AntMan's Second Cardboard Scratch Build

You make it look sooooo easy! Nice job.

After seeing your threads, I've been inspired. I had the idea of building my helmet the same way (cardboard), but brushing fiberglass resin over the entire mask/dome. I figure the resin will soak into the cardboard and give it some extra strength.

Has anyone tried this?
 
Hey guys,

I'm new to the site and just want to thank antman!!! This helps me out tremendously!!!! I am going to start my own cardboard soon!!! Thanks so much!!!!

AF
 
Thanks for the comments guys, much appreciated!:)

As for covering cardboard with fiberglass resin, I have no experience in doing that. I guess it could work. But I would do it on the inside of the bucket to gain more structural rigidness. Just my 2 cents.

Now let's get on with the show. 8)


All glued parts should have now dried sufficiently. Let's do a little inspection of what we have already. Remember that I cut an angle to the cheekbones before glueing them in? This pic shows why:

Boba2-063.jpg


It definitely paid off. You can also see the mask layer on top of the bucket. This makes quite a rigid composition.

And as you also might remember (if not, just scroll up) I used the "Inner Surface" template for the bucket which is a bit smaller in height compared to the mask template. And that is apparent from this picture:

Boba2-062.jpg


When glued on correctly, it creates sort of a rim or ledge (red circle). Now this is makes it easy for the base of the dome triangles to adhere to, as will be apparent later on.

For practical reasons I took off the dome frame arches previously. Now it's time to glue them back on:

Boba2-061.jpg


So now it is time to get busy on the dome triangles! They had plenty of time to dry up so let's use those babies.;)

I start off with the cardboard piece I made from this template:

Boba2-066.jpg


This one forms the back of the dome, and I split it up half (three sections each) and glued them on the inner ledge of the mask:

Boba2-064.jpg


Inside view:

Boba2-065.jpg


As can be seen from above photograph, I left just a little more length on the bottom part of the triangles. This exactly compensates for the aforementioned rim/ledge. So the actual length (arched area in the WOF template) which I leave on the triangle bottom, is the same distance from the dome base ring to the top of the mask edge.
To illustrate, this is where I cut the bottom (red line):

Boba2-066b.jpg


This excess material is covered by and glued to the inner mask edge. That same extra length I also incorporated for the dome form rings:

Boba2-067.jpg


I hope I made that clear :confused. Most of the time, trying to explain what I did is the hardest part of posting. But if anything is not obvious, please LMK as usual.

Okay, let's proceed to glue the triangles to one another; start by glueing both triangles marked number 10 (see WOF template) to the dome frame ring. Then the adjacent triangle number 9 gets glued to number 10, and number 8 to number 9. But take the time to let each part dry thouroughly before you glue it to the next. Use your fingers to mold and shape the triangle in the required curve when glueing. Again, patience is the key here.

Boba2-068.jpg


Next up are these two parts which connect to the glued-in back section and form the side and front of the dome:

Boba2-070.jpg

Boba2-071.jpg


Here's a close-up of them pointy bits stuck together:

Boba2-069.jpg


I just continue in the same fashion for the rest of the triangles; start to glue from the dome frame rings and then connect to adjacent triangle parts.

The pre-shaping with the misting bottle paid off nicely (y). It makes it easier to glue the parts together:

Boba2-072.jpg



Boba2-073.jpg



Boba2-074.jpg



Boba2-075.jpg


By this time I always seem to remember the template part which I forgot to incorporate earlier!:eek:
Here it is:

Boba2-076.jpg


Taped together as depicted, WOF template pages 11 and 12 form the "Helmet Base". This particular template helps in determining the bottom shape of the bucket, as does the "Dome Base" (pages 9 and 10) for the top shape. During the shaping of the wet cardboard Inner Surface, the main form of the bucket is somehow automagically created. So now let's test to see if it makes the correct fit:

Boba2-077.jpg


It duz, it duz!!(y)

Boba2-078.jpg


If it wouldn't have, just use the misting bottle and spray the bucket a tiny bit moist and shape it accordingly.

Only a few more triangles to go:

Boba2-079.jpg


Almost there....

Boba2-080.jpg


And shazam! The dome is complete!:D

Boba2-081.jpg


The basic shape looks okay to me:

Boba2-082.jpg


Here you can see that (even:lol:) I messed up a bit :facepalm. Some triangles where not glued symmetrically, so I had to compensate but cutting excess material away. But this should not be a big showstopper since the dome will receive a thick coat of filler anyway.

Boba2-083.jpg


The areas marked red are to be corrected by either cutting away or by filling up. Keep confidence. It will work out okay.

Boba2-084.jpg


Inside view:

Boba2-085.jpg


Looks nice! :cheers
And here's the last one for today:

Boba2-086.jpg



That's it for the cardboard part of the dome. To make it nice and smooth I'll have do some cutting and basic sanding and to apply filler. But first I think I will focus on creating the "ears". But that is for next time.


Thanks for looking!:)
Peter
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"With great power comes great responsibility"
 
Dude, you rock with the cardboard! Great job! I love the detailed pictures. You bring a whole new dimension to the Scratch-Built world.

I'm doing the same thing with an Imperial Guard helmet (my V.2 found here). I haven't updated it in a few days, though. I really don't know what kind of cardboard I have either.

But, I do like seeing what you have here. Rock on!

David.
 
I am absolutely astounded how this has turned out. I hope you realize how helpful this tutorial is going to be for all of us scratchbuilders. I for one am going to follow this step by step when I'm able to start my second bucket. Amazing work! I think this thread should be stickied as THE example for all future scratchbuilders!

Sam
 
Looks great Ant !! This is so helpful, I just started my first scratch build. Right now I'm just doing a thin cardboard mock-up to learn the process and how the parts go together. I was going to use the "For Sale" sign type but after seeing this I may change my direction. LOL or I may just do both. Keep it up man. Awesome !!!!



O.A.
 
Hey Peter... you not finished yet bruv?? whats the hold up! (JK) :lol:

I don't think you could fathom how helpful this thread is to the masses of scratch builders out there!
I vote for this to be Stickied... (y)
 
Sticky!

AntMan, your scratchbuilding prowess is unreal! You present the process in such a clear-cut manner, that any idiot like me can follow the step by step instructions and come out with a decent looking bucket. :)

I am excited to see what else you do with the current build!

-Paul
 
Great job! .... I really don't know what kind of cardboard I have either.
Thanks David! To me it looks like you are using the corrugated type. But I might be way off :lol:
I for one am going to follow this step by step when I'm able to start my second bucket. Amazing work!
Thanks Sam! I'm lookin' forward to your next scratch build, 'cause I like the first one you did (y)
Very nice! The tutorial is coming along great as well.
Glad you like it!
This really helps me ! Thanks Antman.
No problemo Luke!;)
Looks great Ant !! This is so helpful, I just started my first scratch build.
Yes! Be sure to post lots of pics of your scratch build dude! Thanks:)
WOW! That looke awesome, Great stuff Antman!
Thanks man!
Hey Peter... you not finished yet bruv?? whats the hold up! (JK) :lol:

I don't think you could fathom how helpful this thread is to the masses of scratch builders out there!
I vote for this to be Stickied... (y)
Hey Gav! This ol' thread too slow for ya? Haha! Glad you like it bro. And thanks for the sticky vote, but I guess it can only get sticky if I complete the tutorial. So I HAVE to make it perfect. Oh the pressure! Eye cannae take anymurrrrrrrrr!;) Thanks bro!(y)
Yes Mojo! It should be stickied! AntMan, you're making an awesome cardboard helmet!!! ;)
Okay, okay, you convinced me! I'll do my best to make it sticky-worthy Thanks!
I'll throw in sticky vote as well.
:cheers
...any idiot like me can follow the step by step instructions and come out with a decent looking bucket.
I know there's a compliment in there somewhere...
Just kidding dude!:lol: Thanks!;)
Let's see you progress!


Now it's been a while since I've posted any updates. Here in Holland we've been enjoying my son's two week school holiday. I took leave from work and spent some QT with the family! And good it has been, as the climate temp rose to a very comfy 28 degrees Celsius! Thus I did not have a lot of time for crafting and posting. Too much sand on the beach for that anyway!:D
So apologies for the delay, but I promise to be back soon with some work done on the ears. ;)

Stay tuned
Peter
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"With great power comes great responsibility"
 
Hi!

Found a wormhole and travelled through it to create a moment in time to report on my progress. I figured it has been tooo long since I posted any progress, eventhough I decided to post only when I would be finished with a particular part. But since I am almost done with this part of the bucket I couldn't hold back the pictures from all of you faithful viewers!:)

Well, as promised here's what I did on the "ears". I chose for the ears to be a solid construction instead of a hollow one. This means I will have to
build up the ears out of different layers of cardboard glued to one another and then cut, chissled and sanded into shape. It sounds more difficult
than it is, but it does require some skill. But if I can do it, you can too! (y) Now let's get started.

First I start off with this WOF template (page 6):

Boba2-093.jpg


I cut out the template for the left ear, and also the gutter in it, and make a test fit on the bucket:

Boba2-094.jpg


Boba2-095.jpg


Next I transfer the template six times on a piece of cardboard as such:

Boba2-096.jpg


From two pieces, I cut out the gutter part as depicted here:

Boba2-097.jpg


Then I start cutting as precise as possible on the outlines:

Boba2-098.jpg


Because the ear will have a surface angle I precut the material which needs to be sanded off anyway:

Boba2-099.jpg


Stacked, the layers form this shape:

Boba2-100.jpg


To be cut and sanded until it looks like this:

Boba2-101.jpg


I glue two layers at a time together and press 'em including the supporting material:

Boba2-103.jpg


Boba2-102.jpg


Then those two are glued to eachother the same way:

Boba2-104.jpg


Boba2-105.jpg


While this is drying I prepare for the R/H ear sections by cutting out the templates (page 7) and transferring them to cardboard. I drew plenty of shapes (because secretly I'm doing a second bucket simultaneously)8):

Boba2-106.jpg


I start cutting out the easiest part which consists of 4 layers (three shapes as depicted in next pic, plus the back-plate) and glue them together in the same way as described above. :

Boba2-107.jpg


The edges of this piece are sanded (grade 120-150) until smooth and straight.

Next I tackle the most intricate and complex part (to me at least) which consists out of 7 layers. The design looks quite simple but has so many
angles and sharp edges to it, it needs full attention when constructing it:

Boba2-108.jpg


The basic idea is the same as with the left ear piece; cut away material which you are going to cut away anyway as if you were sculpting the shape from a solid piece of stone or something.

Building up the layers:

Boba2-109.jpg


Boba2-110.jpg


And all of the prep'ed layers stacked look like this:

Boba2-111.jpg


So then it's just glueing them together and shaping 'til the desired shape appears:

Boba2-112.jpg


Boba2-113.jpg


Here's the lot so far:

Boba2-114.jpg


Also cut the bottom angle of the left ear:

Boba2-115.jpg


Sanded smooth:

Boba2-116.jpg


Finally it is time to create the "ear cap", built up out of 4 layers:

Boba2-116a.jpg


White glue all over the place:

Boba2-117.jpg


Two layers at a time:

Boba2-118.jpg


Good old glue clamps&blocks:

Boba2-119.jpg


The cap goes on top of the firstly created right ear piece:

Boba2-120.jpg


Shaping the angle is the same story; use a fresh sharp knife to roughly cut away excess material being careful not to cut away too much:

Boba2-122.jpg


All it needs now is some sanding until smooth and I'm set to put on the first layer of sealing agent. But that is for next time.

Greetings from Delft,
Peter
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AntMan...this is simply awesome! I wish this tutorial had been available to me when I was scratchbuilding mine....your attention to quality craftmanship and detail is amazing and commendable....I also vote it as a sticky, and I have been sending it to other Mando's as reference, who are trying to build their own helmets...keep up the good work!:)(y)
Rob
 
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