Animefan Boba Fett helmet build

  1. #1

    Animefan Boba Fett helmet build

    Hi guys, I'm new to the Boba Fett costuming scene but have been busy these past few years building a ROTS Clone Trooper.

    A few weeks ago I came across the opportunity to pick up one of animefan's Boba helmets and thought why not, it looks like a fun side project

    So here I am now a few weeks after receiving the helmet and would like to show some progress.

    Right from the start I gave all the parts a good wash, then prepped Boba for some dental work with a dremel:



    I carved out the visor with minimal collateral damage (which would have been fine if I was doing a fully weathered helmet, but more on that later). After further sanding and lots of minor body filling work, here is the helmet ready for the paint stage:



    Animefan's helmet had an ESB-style circuit board already molded into the keyslots in the back of the helmet, but I decided to carve them open to insert a separate ROTJ-style circuit board (the filled scratch marks on either side of the slots is where I got too eager with filing and ended up gouging out some of the surface):



    Here's all the extra parts of the ears and rangefinder, cleaned, sanded and filled:



    As this is my first Boba helmet, I had a great time poking around the forum and reference galleries, learning about the subtleties of the Boba Fett helmet and all its parts. I really want to make this helmet as screen-accurate as possible, so I ended up thinning down the inside edge of the visor (it was quite thick after dremeling out the visor).

    I also discovered all about the borden connector and the polaroid lens cap in the rangefinder. The polaroid cap was easy enough (I just filed out one edge to make it look more like the real thing).

    The borden connector in this kit needed a lot of work to make it screen accurate, as it was based on an actual borden which was further modified on the screen-used helmets. I first grinded it down as it was way too thick to sit in the helmet. Then I realised that the holes were flipped around the wrong way, with the smaller two holes sitting on the right under the larger hole, rather than the left. I also discovered that the side hole needed to be slightly smaller than its neighbour...

    That probably doesn't make much sense to those unfamiliar with these helmets :P, so long story short, I sealed the side hole and hand-drilled another one in the correct position and size:



    I'm pretty happy with the result. Once painted the original hole should disappear (hopefully).

    Now I need to decide how I'm going to paint this beauty. This helmet doesn't have Boba's trademark dent, so I was thinking of doing an all-white Supertrooper. But then I had another thought... I know it's not technically canon, but if I gave this helmet a satin white finish and weathered it, it might look pretty good with the Clone Trooper armour I'm building. I could always just make it a Supertrooper (gloss white, no weathering), but I'm not sure if it would match nicely enough then.

    Either way, I'll start by painting the inside of the helmet black to help hide the wearer's face.

    That's all for now, thanks for watching!

  2. #2

    Re: Animefan Boba Fett helmet build

    I've made some more progress after deciding how I'll be fixing everything together. Starting with the rangefinder's ear cap, I've decided to uses nuts and bolts to make the entire assembly removable, just in case something ever breaks in the future, or if I decide to repaint the helmet. At this stage this baby's going to be a Supertrooper

    Here's the inner and outer ear cap before and after adding some screws and holes:



    I hand-drilled some shallow small holes just big enough for the heads of the screws to sit in, giving them a nice alcove to stick to. I used epoxy glue to set them in place, so they're now rock-solid.

    Here's the counterpart holes drilled into the helmet:



    After tweaking the holes to ensure a clean fit, here's the result:



    The screws will be secured with washers and nuts on the inside, and another screw will go through the base of the rangefinder stalk to ensure that it can't slip out. More soon!

  3. #3
    Overlander's Avatar
    Member Since
    Nov 2013
    From
    San Diego, CA
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    7

    Re: Animefan Boba Fett helmet build

    Hi RetiredClone,

    Very cool that you are going to complete the helmet as a supertrooper! Are you considering the entire costume?

    I am just in the process of beginning a supertrooper costume. I am already a sandtrooper in the 501st (TD-50176).

    I am considering the animefan helmet for my costume. Thanks for documenting your helmet build!

  4. #4

    Re: Animefan Boba Fett helmet build

    That's awesome, all the best for your build! At this stage I'm just doing the helmet, although I'm quite fond of this piece of Ralph McQuarrie's concept art - I might one day do a non-canon costume with this helmet and the rest of the suit based on that image...

    Now down to business...

    After logging a few more weekends into this build, I've made some good progress. With this project I decided to try and avoid glue as much as possible, so the ear caps and visor will be installed with Chicago screws. Here's a bunch of the external parts with screws ready for use:



    For the rangefinder, I've drilled some small screws into the top of the stalk and made some holes to hold the topper in place:



    I've done it this way so that my JC27 light kit will fit snugly inside the topper without interfering with the screws.

    Here's the hard hat liner that should make the helmet comfy to wear:



    It's a standard hard hat with the side connection points cut out and a half-circle bracket made to hold them together. Good old velcro will keep it attached inside the helmet to avoid using glue.

    Here's the visor installed inside the helmet with Chicago screws and rubber washers:



    Unfortunately I made a critical mistake of drilling a hole too close to the edge of the visor and it snapped clean in half (gaaaahhhh!). I managed to glue it back together so there's only a minimal crack line visible from the outside, so it can stay that way for now.

    At last, here's the whole package:



    Getting the mandibles to sit right and look the part turned out to be extremely hard, but thanks to a trusty heat gun and a lot of comparisons to reference pics, I think it turned out well. I think the ear caps need to taper more away from the helmet, so I might build up the surface on the sides to help. Next up is the rangefinder topper assembly. More soon!

  5. #5

    Member Since
    Oct 2013
    From
    Juneau, Alaska, United States
    Posts
    71

    Re: Animefan Boba Fett helmet build

    would it be possible to get the dimensions of that range finder end?

  6. #6
    RafalFett's Avatar
    Member Since
    Oct 2010
    From
    Galati, Romania
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    2,641

    Re: Animefan Boba Fett helmet build

    bpwmd said: View Post
    would it be possible to get the dimensions of that range finder end?
    All you need is here ==> Rafal Works Helmet (RWH) v2 Helmet Templates and Build at the end of the first post and in post #32.

  7. #7

    Re: Animefan Boba Fett helmet build

    bpwmd said: View Post
    would it be possible to get the dimensions of that range finder end?
    Sure, this range finder topper is almost identical to RafalFett's, here's the dimensions when viewing it front-on as in the photo above:

    Width: 70mm / 2 3/4 inch
    Height: 22mm / 1/8 inch
    Depth: 37mm / 1 7/16 inch

    Hope that helps!

  8. #8

    Member Since
    Feb 2014
    From
    Colorado
    Posts
    47

    Re: Animefan Boba Fett helmet build

    That visor placement looks top notch. Good job RetiredClone!

  9. #9

    Re: Animefan Boba Fett helmet build

    Really nice work, is there anything you would have done differently if you were to start over?

  10. #10

    Re: Animefan Boba Fett helmet build

    SaintHubbins said: View Post
    That visor placement looks top notch. Good job RetiredClone!
    Thanks! Even with the seam line where the visor snapped I'm happy how it turned out.

    Tobot said: View Post
    Really nice work, is there anything you would have done differently if you were to start over?
    Thanks I can't really think of anything I would do differently, although this is the hardest helmet I've built so having that info would have been helpful

    ...

    Time for an update! Jumping ahead a bit - I've since finished this helmet and had my very first informal troop at a convention. Here it is finished:











    And its debut at Oz-Comic Con:



    I couldn't get the paint finish to be uniformly glossy and parts of the surface have pin holes and weird patterns, but I think at this stage I'm happy with the way it turned out. It's been a lot of work and a long journey, but worth it in the end!

  11. #11
    RafalFett's Avatar
    Member Since
    Oct 2010
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    Galati, Romania
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    2,641

    Re: Animefan Boba Fett helmet build

    The helmet looks great! I love that you added the 2 dental files in the rear keyhole. I think you should darken a bit the left front arrow color (the blue one). Keep up the amazing work!

  12. #12

    Re: Animefan Boba Fett helmet build

    Thanks! I really appreciate the positive feedback

    I couldn't find any reference photos of the Super Trooper showing the key slots in the back of the helmet, so I made a guess with the dental files - no idea if they were in the original helmet or not. I also couldn't tell how dark the blue arrow was on the reference pics, but making it darker should be an easy task. Thanks again!

  13. #13
    RafalFett's Avatar
    Member Since
    Oct 2010
    From
    Galati, Romania
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    Re: Animefan Boba Fett helmet build

    RetiredClone said: View Post
    Thanks! I really appreciate the positive feedback

    I couldn't find any reference photos of the Super Trooper showing the key slots in the back of the helmet, so I made a guess with the dental files - no idea if they were in the original helmet or not. I also couldn't tell how dark the blue arrow was on the reference pics, but making it darker should be an easy task. Thanks again!
    I have a thread that discussed this feature here ==> Dental Files On The Supertrooper Helmet?

  14. #14
    Notlewis's Avatar
    Member Since
    Mar 2005
    From
    Germany, Stolberg NRW
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    Re: Animefan Boba Fett helmet build

    That helmet looks great! I also like the fitting with your tie and suit!

  15. #15

    Re: Animefan Boba Fett helmet build

    Notlewis said: View Post
    That helmet looks great! I also like the fitting with your tie and suit!
    Thanks for the feedback! The helmet did match the suit quite well in the end

    Just for fun, here's a photo of the helmet completely disassembled:



    I also managed to get Animefan's V2 range finder stalk to work with JC's LED light kit. At the top of this stalk is a screw and the hollow brass pipe normally used to thread wires for certain LED light kits. I carved off a small amount of the screw and the top of the brass pipe, then added an extra screw between them to attach the RF topper with a nut on the inside. With the screw in the middle, JC's LED light kit fits inside the topper without touching the screw:


  16. #16
    Jc27's Avatar
    Member Since
    Jun 2012
    From
    Pennsylvania
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    1,755

    Re: Animefan Boba Fett helmet build

    Glad it works out for you, I hope you like it.

  17. #17

    Re: Animefan Boba Fett helmet build

    You did a great job putting the helmet together

  18. #18

    Re: Animefan Boba Fett helmet build

    Jc27 said: View Post
    Glad it works out for you, I hope you like it.
    Thanks JC! I'm very happy with the light kit, it's a nice snug fit with the mods I made to the top of the RF stalk.

    animefan said: View Post
    You did a great job putting the helmet together
    Thanks Ryan I had a blast and it was a great learning experience.

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