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  1. Member Since
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    Mar 9, 2015, 3:51 PM - 1st Helmet Build (Cardboard Fett) #1

    Hey everyone, my name is Trevor and I'm up here in Minnesnowta making a Boba Fett helmet. I have been using these forums and several member's threads as a guide, and figured I would finally join the group and stop just creeping around lol.

    I also decided to start a thread to post my progress and will put some pictures and more details about what I have got done so far very soon. I hope that's fine!

    Will update as soon as I have some time. Hopefully today, thanks!
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  3. BobaFiend's Avatar
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    Mar 9, 2015, 5:41 PM - Re: 1st Helmet Build (Cardboard Fett) #2

    Welcome to the community, congrats on post #1. You've taken your first step into a larger world.
  4. Mar 10, 2015, 5:54 AM - Re: 1st Helmet Build (Cardboard Fett) #3

    Always great to see a new Fett in the works! Welcome aboard!
  5. Member Since
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    Mar 10, 2015, 3:31 PM - Re: 1st Helmet Build (Cardboard Fett) #4

    Update!! Alright so I actually started making this helmet a few years ago, and only ever got the basic thing put together and smoothed, but never did the ears, rangefinder, keyhole, dent, etc. Just recently my girlfriend decided to help me start the project back up after the helmet had been sitting on the shelf for a LONG time. We got the ears, rangefinder, keyhole (my failed attempt at one at least) very roughly put together and had started to sand and smooth out all the parts using the templates i printed out years ago and still had... That's when a "OH CRAP" moment happened, just yesterday...

    First off, here are some pictures of the parts.
    dsc_0235-jpgdsc_0231-jpgdsc_0229-jpgdsc_0228-jpgdsc_0219-jpg

    Now as you can tell, the keyhole I made was cut out very roughly. I actually had decided to try and fiberglass it and sand it back down and was going to dremel the slots to smooth perfection.. obviously I gave up and threw it away and am going to start that one over again! The rangefinder, I have no idea why I am using the quickweld to reinforce it, but I am liking the strength it has and just need to sand it down now.. The other parts are going well, and I am pretty proud of those actually.. But the "OH CRAP" moment was when I started to measure things and realized everything was way too big, literally up to 10mm too big in certain areas. SO I printed out some new templates, and realized that back in the day when I printed my templates out I let the printer software stretch them all out to fit the paper..

    Therefore everything we have done, including the helmet itself is way too big and I have to pretty much start over. Although it isn't such a bummer because my girlfriend actually wants to make a helmet also, so this time we are both going to make them at the same time. Starting today!

    I will post more pictures as we go, including the helmet that I HAD done, and update on the progress.
  6. hamsandwich72's Avatar
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    Mar 10, 2015, 3:46 PM - Re: 1st Helmet Build (Cardboard Fett) #5

    Quote Bebommib said: View Post
    Although it isn't such a bummer because my girlfriend actually wants to make a helmet also, so this time we are both going to make them at the same time. Starting today!
    Hold on to that one as long as you can!
  7. Member Since
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    Mar 10, 2015, 10:28 PM - Re: 1st Helmet Build (Cardboard Fett) #6

    Quote hamsandwich72 said: View Post
    Hold on to that one as long as you can!
    LOL trust me, I know!

    All we got done today is the supports for the base, using Rafalfett's templates. Took longer than we thought because the only 2mm thick cardboard we found is super heavy duty stuff. Not easy to cut at all. (The one on the right is mine, while the one on the left is Sara's) As of right now they look the same obviously but I feel like it's going to turn into a slight competition =p

    Looking good so far though I think!
    dsc_0248-jpgdsc_0245-jpgdsc_0247-jpg

    ..Oh yeah, and I get a celebratory beer, so I'm happy
  8. Member Since
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    Mar 12, 2015, 12:19 AM - Re: 1st Helmet Build (Cardboard Fett) #7

    Today, we worked on the helmet for about 5 hours, but we must be slow or something because we only got a couple things done lol.

    This is what they look like now
    dsc_0255-jpg

    We got all the inner layers cut out as you can see behind the helmets, and got them curved but are going to wait until tomorrow to actually attach them and continue because it got a little late.

    dsc_0254-jpgdsc_0253-jpg

    Also we got the little strips around the top back attached, and beveled nice and flush with the rest of the dome base.

    I work the next three days, so might not be able to update as often on here, but will be taking pictures of progress when we get time to work on the helmets.
    Will update as soon as I can!!
  9. RafalFett's Avatar
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    Mar 12, 2015, 1:59 AM - Re: 1st Helmet Build (Cardboard Fett) #8

    Great build so far! If you need any assistance with the build, just let me know and I'll help you gladly.
  10. Member Since
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    Mar 12, 2015, 1:05 PM - Re: 1st Helmet Build (Cardboard Fett) #9

    Thank you so much! And will do!
  11. hamsandwich72's Avatar
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    Mar 12, 2015, 2:30 PM - Re: 1st Helmet Build (Cardboard Fett) #10

    Quote Bebommib said: View Post
    Today, we worked on the helmet for about 5 hours, but we must be slow or something because we only got a couple things done lol.
    Ha! I've been working on my helmet for almost two years now. Slow and steady, brother...
  12. Member Since
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    Mar 15, 2015, 12:38 PM - Re: 1st Helmet Build (Cardboard Fett) #11

    Hey everyone! Just a little update on progress:
    We got the inner layer and the outer layer onto the helmet, and the little strip on the back inside of the dome base. Also we took out all the inner supports! So right now we are working on getting the cheeks in, then the keyhole. Starting to realize that getting the cheeks in, and cutting the little slots on the keyhole smoothly is WAY easier said than done.
    I have been at work the past few days so I haven't had time to take many pictures, but I'll try to get some posted later!
  13. Member Since
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    Mar 16, 2015, 12:48 AM - Re: 1st Helmet Build (Cardboard Fett) #12

    Today we managed to each get one side of the cheeks in. Not perfect, but only a couple mm off almost anywhere. Nothing a little putty or sanding can't fix!
    img_20150316_004121-jpg

    And Sara being impatient to wear her helmet ! Lol
    img_20150316_004227-jpg
  14. RafalFett's Avatar
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    Mar 16, 2015, 1:30 AM - Re: 1st Helmet Build (Cardboard Fett) #13

    Looking good! Keep us posted with your updates!
  15. Member Since
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    Mar 18, 2015, 5:32 PM - Re: 1st Helmet Build (Cardboard Fett) #14

    Quote RafalFett said: View Post
    Looking good! Keep us posted with your updates!
    Thanks!!
  16. Member Since
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    Mar 18, 2015, 5:43 PM - Re: 1st Helmet Build (Cardboard Fett) #15

    Alright so just a quick update on the progress we have made:

    We both got our other cheeks put in, it took a lot of careful fighting with the cardboard to get them to fit in right and with the correct curves, etc but we pulled it off after many hours lol one of Sara's cheeks is a few mm low on a side though so we may have to melt the hot glue and pull it up further. When I post the pictures I am hoping I can have some opinions on if that's necessary or not.

    We also got our keyholes made and are in the process of reinforcing them on the back side a a tiny bit of wood glue at a time, as that seems like it will be difficult after they are actually in the helmet. Sara's keyhole looks flawless, where as mine is a little bit.. Not as flawless . Again hoping for opinions when I put the pictures up.

    We both have also reinforced the edges of the dome base from the inside just to make sure the outside rim will be sturdy for building the dome on top of.

    Other than that, its been a lot of little touchups and applying wood glue to strengthen things from the inside mainly since we have been working a ton lately. After tomorrow I have a 5 day weekend so will definitely be putting pictures up and hoping to finish everything up! (At least the cardboard part of it )

    Thanks !
  17. Member Since
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    Mar 22, 2015, 2:34 PM - Re: 1st Helmet Build (Cardboard Fett) #16

    I finally have some free time to get pictures up. These are taken with a phone though so sorry about the quality =(

    These first pictures are of my helmet after I got the second cheek in. We are trying our best but I know they are not perfect after looking at other's threads. I do reference the measurements that rafalfett posted on his thread though and nothing is more then 2-3mm off at any point, and most of it is exact.
    img_20150321_204206-jpgimg_20150321_204149-jpgimg_20150321_204233-jpg

    I'm hoping that I can get some feedback on anything that may look like it needs to be redone though, anything that you guys think sanding/putty and bondo won't fix.


    This is Sara's helmet after she got her second cheek in also.
    img_20150321_204458-jpgimg_20150321_204435-jpgimg_20150321_204447-jpg

    As you can see her left cheek is a bit low, but when I measured the visor from the top corner to the bottom of the helmet it seems that it was actually the visor area that was 2mm too short, and the cheek that is low was actually at the correct distance from the top. This is a big one that I'm hoping for some feedback on.

    My keyhole:
    img_20150321_204324-jpgimg_20150321_204306-jpgimg_20150321_204340-jpg

    Sara's keyhole:
    img_20150321_204607-jpgimg_20150321_204558-jpgimg_20150321_204622-jpg

    Our keyholes took us a lot of time because the slots kept ending up rough and the layers would peel away when the board was curved. We ended up taking our 2mm board and pretty much slicing it in half by peeling layers off until it was 1mm. That made the cutting way easier and also the board didn't peel away or get rough when curved. I realize the slots are still a little rough but we wanted to just get them put in for now, and later we are going to smooth them out more.

    We then cut out the dome base and left a 15mm area for the supports
    img_20150321_215139-jpg

    It was tricky trying to get the supports nice and flush/straight and exactly centered on the front/back and left/right lines but we got a couple of them on perfectly and this is where we are at now.
    img_20150322_021257-jpgimg_20150322_021334-jpgimg_20150322_021323-jpg

    The way that we put the strips on was using wood glue underneath them, and when they were in place using hot glue almost as a clamp to hold them in place.
    I know we could have just used hot glue, but better safe than sorry.
    We are planning on putting in all of optional supports also to give us a little more precision when we get to laying down the dome strips.


    Feedback is greatly appreciated!! I don't mind some constructive criticism, I know we could probably use some lol
    ..off to try and get the rest of those supports in! Thanks all!
  18. RafalFett's Avatar
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    Mar 23, 2015, 11:56 AM - Re: 1st Helmet Build (Cardboard Fett) #17

    I can say that both of you are doing a great job following my step-by-step guide, so there's nothing to comment so far. Keep up the awesome work!
  19. Member Since
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    Mar 24, 2015, 11:58 PM - Re: 1st Helmet Build (Cardboard Fett) #18

    We worked on our helmets all day yesterday, and again all day today. Probably put a little over 10 hours of actual work-time into the dome. I can see now why I can't find any threads with people putting in all 12 support beams, it was intricate, frustrating, and time consuming. But it paid off big time, I could probably stand on top of my helmet it is so strong now, not that I would ever think of attempting such a feat =p

    This is what they looked like with the supports put in:

    dsc_0298-jpgdsc_0297-jpgdsc_0292-jpgdsc_0291-jpgdsc_0290-jpgdsc_0287-jpgdsc_0295-jpgdsc_0294-jpg

    Progress..

    dsc_0300-jpgdsc_0305-jpg


    ..and here are some pictures from tonight!!

    Sara's Helmet -
    dsc_0319-jpgdsc_0314-jpgdsc_0315-jpgdsc_0316-jpgdsc_0317-jpg

    My helmet -
    dsc_0321-jpgdsc_0326-jpgdsc_0320-jpgdsc_0324-jpg

    Side by sides -
    dsc_0332-jpgdsc_0329-jpgdsc_0328-jpg

    I'll keep updating when we start to get the ears/rangefinder going, but again I work the next few days so it may not be until the weekend. We are both getting really excited though!
  20. RafalFett's Avatar
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    Mar 25, 2015, 1:36 AM - Re: 1st Helmet Build (Cardboard Fett) #19

    Oh my... Both helmets looks more than great! May I suggest to use a thinner cardboard for the dent, as this is a small part and once glued in place, it will be a sturdy part of the helmet. Also you can level the dome back strip and the rear keyhole lower part (only the pieces that sticks out on your build):

    dsc_0326-jpg img_20150321_204306-jpg
  21. Member Since
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    Mar 25, 2015, 10:43 AM - Re: 1st Helmet Build (Cardboard Fett) #20

    Quote RafalFett said: View Post
    Oh my... Both helmets looks more than great! May I suggest to use a thinner cardboard for the dent, as this is a small part and once glued in place, it will be a sturdy part of the helmet. Also you can level the dome back strip and the rear keyhole lower part (only the pieces that sticks out on your build):

    dsc_0326-jpg img_20150321_204306-jpg


    Thank you!! I'll level those out as soon as I get a chance =) Also, for the dent are you talking about the slices that are put into the hole? I could peel the cardboard in half to make it close to 1mm, do you think that would work better?
  22. RafalFett's Avatar
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    Mar 26, 2015, 3:21 AM - Re: 1st Helmet Build (Cardboard Fett) #21

    Quote Bebommib said: View Post
    Thank you!! I'll level those out as soon as I get a chance =) Also, for the dent are you talking about the slices that are put into the hole? I could peel the cardboard in half to make it close to 1mm, do you think that would work better?
    It could work well that way, but if not, you can always find a thin cardboard piece at home (book covers, cereal box and so on).
  23. Member Since
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    Mar 26, 2015, 12:30 PM - Re: 1st Helmet Build (Cardboard Fett) #22

    Quote RafalFett said: View Post
    It could work well that way, but if not, you can always find a thin cardboard piece at home (book covers, cereal box and so on).
    Sounds good, thanks Rafalfett!!


    A couple updates/notes about what we are working on right now:

    - I forgot that I never mentioned the fact that Sara is not actually making a Boba Fett helmet, she is thinking about making it a Rav Bralor helmet. I know that we made it with all the dimensions and the asymmetries of Boba Fett, but we will figure that out and fix those if we have to when we get to sanding/bondo.

    - We are both planning on incorporating electronics into our rangefinders, and are going to radioshack today to look around. I have looked through a ton of threads/guides about doing so but I just don't really understand it all that much. And I don't want to buy a kit as I tend to feel more proud when I can do everything myself. I know I need a low profile servo, and some kind of control board, etc. and I think I may buy an Arduino board but again I have no idea what I'm doing really. If anyone could chime in on whether an Arduino board will work for this, it would really help a ton. Also what else I will need to make the rangefinder move other than the board and servo. I would really appreciate it.

    - For the dome, I am planning on coating the inside/outside with minwax polycrylic protective finish first to make sure the cardboard is nice and sealed and waterproof. Then I think I will use bondo glass on the inside to reinforce the dome even more before we really start sanding and finishing up the outside. I am also going to use a thin layer of spackling paste or glass on the outside as usual.
  24. Member Since
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    Mar 26, 2015, 10:20 PM - Re: 1st Helmet Build (Cardboard Fett) #23

    We went to Micro Center today and I got a bit excited.. Came home with two arduino boards and lots of extras!!
    img_20150326_221708-jpg
  25. hamsandwich72's Avatar
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    Mar 27, 2015, 8:09 AM - Re: 1st Helmet Build (Cardboard Fett) #24

    Well, an Arduino might be a bit overkill if you are only interested in moving the servo and blinking lights. You could probably get away with an Arduino Nano, TinyDuino, or Arduino Pro Mini. I'm just thinking about having enough room in the bucket for your noggin.
  26. Member Since
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    Mar 27, 2015, 10:38 AM - Re: 1st Helmet Build (Cardboard Fett) #25

    The reason I didn't get one of the micro ones is because I am planning on using the one board to run the lights, servo, LCD on the chest piece, and have it all controlled with the wireless remote. I don't know much about these things so I wasn't sure if one of those mini guys would be able to do all that. If they are, than I'm sure I can grab one a couple of those in the future instead, since the boards themselves aren't much money that's no big deal.
    Ham you seem to know about these? Will one of those mini boards run all that?

    Either way if I have to buy a couple tinyduinos, or nanos and be left with a couple unos.. Ill find something cool to do with them! Haha

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