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  1. never_ending_fett's Avatar
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    Aug 10, 2007, 4:05 PM - Re: Anyone ever done a vac-Formed Helmet? #26

    This does sound like a great idea for paint practice/variations and customs. I'd eventually (like a looooong time from now) like to have multiple complete costumes PP2, ESB, ROTJ, etc. anyway and this might be a more economical way to do it.
  2. TeamFett's Avatar
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    Aug 10, 2007, 4:10 PM - Re: Anyone ever done a vac-Formed Helmet? #27

    Eventually I would also like to have every version of Fett (but only the helmets), and this is a great way to accomplish something like that without taking a loan out on the bank.
  3. corby's Avatar
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    Aug 10, 2007, 4:18 PM - Re: Anyone ever done a vac-Formed Helmet? #28

    a bucket at $50-100? I would definitely be interested in that since I'm on a very tight budget. this sounds like an awesome idea
  4. Rich D.'s Avatar
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    Aug 10, 2007, 4:53 PM - Re: Anyone ever done a vac-Formed Helmet? #29

    Quote tubachris85x said: View Post
    You would use a negative mold for vac-forming. Vac-forming is taking a sheet of plastic, heating it up till its soft, and then placing it over a mold on a table with a vaccum attached, and pressed over the mold, with the suction of the vac, pulling the soft plastic around the mold until the plastic cools.
    Quote Aaron said: View Post
    It appears that someone has tried this, with impressive results - http://www.tk560.com/blaxmyth/blaxmyth.html
    This is an example of vacu-forming over a positive mold. The details seem to be okay because the plastic he used is pretty thin. Ideally it would be a negative mold, so the details would be more crisp.

    I'm really interested in this from a durability/troopability perpective. It would be great to have a helmet that I could let someone else put it on without being stressed that it would shatter if they dropped it.
  5. R2-JD's Avatar
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    Aug 10, 2007, 8:11 PM - Re: Anyone ever done a vac-Formed Helmet? #30

    Quote hellopike said: View Post
    JD,

    I'd definitely like to see pictures of the helmet! I'm interested in seeing how its looks vac-formed, and as a fan-made helmet made nearly 15 years ago.


    Post those pictures!

    Phil
    All right, I took some pictures of my MARCO vac-formed Boba Fett helmet. Sorry for the crappy photography. I wanted to take them in sunlight but it is raining here right now.

    Follow this link: MARCO Boba Fett helmet

    JD
    Last edited by R2-JD; Aug 10, 2007 at 10:11 PM. Reason: Fixed link, hopefully
  6. Member Since
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    Aug 10, 2007, 9:49 PM - Re: Anyone ever done a vac-Formed Helmet? #31

    R2-JD,

    Only 2 of the pictures show up for me...

    But from what I can see, not too bad- especially for that time period!

    Accuracy aside, the Marco helmet is a good example of the kind of detail you'll get with vacuforming. The only two areas where I would be concerned about 'soft' detail are the dent and the 'turn signals'. I do however, think I could improve some over what you see in the Marco helmet.

    A negative mold IS a bit better for capturing detail like this. However, the time and expense of making and using those kind of molds is a bit more than what I was thinking of. It would raise the per-helmet price a bit.

    I was actually considering making the helmet bucks (molds) with no dent at all- that way the helmet could be used for Boba OR Jango OR other customs.

    As far a 'movie sized' helmet goes, I have the one fiberglass helmet that came from a re-worked Don Post Deluxe helmet, and I may have access to a mystery helmet as well. I'm not well-versed in the size difference between those two, so I'd appreciate some input.

    Vacuforming would increase the overall size of the helmet by about 1/8- to me, that's not a big deal. I'd like to hear other opinions though.

    Another part of my plan would be to have the 'visor' part of the overall mold. The builder could just paint it gloss black if it's going to be just a display piece, or cut it out and install a tinted lens.

    Mark
  7. R2-JD's Avatar
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    Aug 10, 2007, 10:10 PM - Re: Anyone ever done a vac-Formed Helmet? #32

    Quote Bradleyfett said: View Post
    R2-JD,

    Only 2 of the pictures show up for me...
    Try the link again, I tried fixing it.

    JD
  8. stormtrooperguy's Avatar
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    Aug 10, 2007, 11:15 PM - Re: Anyone ever done a vac-Formed Helmet? #33

    Quote Bradleyfett said: View Post
    Vacuforming would increase the overall size of the helmet by about 1/8- to me, that's not a big deal. I'd like to hear other opinions though.
    that doesn't sound bad to me.
  9. I helped at SDCC '08 GCNgamer128's Avatar
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    Aug 11, 2007, 7:02 AM - Re: Anyone ever done a vac-Formed Helmet? #34

    Do you guys want me to try to tackle this project? I have access to Mystery helmets, I could have one made to turn into some vacforming bucks.
  10. Aaron's Avatar
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    Aug 13, 2007, 8:27 PM - Re: Anyone ever done a vac-Formed Helmet? #35

    Quote GCNgamer128 said: View Post
    Do you guys want me to try to tackle this project? I have access to Mystery helmets, I could have one made to turn into some vacforming bucks.

    Yes, that sounds good to me.
  11. Member Since
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    Aug 23, 2007, 3:13 PM - Re: Anyone ever done a vac-Formed Helmet? #36

    OK folks, take a look at what I've been working on:








    Keep in mind this is the very first pull of all the parts just to see how it works. Excuse the rough-cut edges here and there- I hacked it up pretty good just to test fit everything. Also, the visor will be filled in on the final mold (working on that today).

    The 'ear' pieces (as well as the rangefinder top, not shown) are resins. The rest is vacuformed styrene (3 pieces; front, back, top). I've determined that the 'turn signals' in front should be cut out with an exacto using a template (which I can provide).

    Also note that this one is a Jango (no dent) version. I figured folks can either add their own dent, or they may not want one at all for custom Mandos. I may also consider making an alternate crown mold with the dent built-in.

    Looks like I can probably do these for around $75 each (shipping extra).

    I'm pretty pleased with the results myself. Everyone let me know what you think.

    Mark
  12. Laan's Avatar
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    Aug 23, 2007, 3:16 PM - Re: Anyone ever done a vac-Formed Helmet? #37

    Wow! That came out pretty darn good man!
  13. Member Since
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    Aug 23, 2007, 3:22 PM - Re: Anyone ever done a vac-Formed Helmet? #38

    Hehe... Thanks! I'm excited about it too. I'm resisting the urge to slam together a few for myself and start painting!


    PS: anyone interesed in one should PM me here.

    Mark
  14. Nobody's Avatar
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    Aug 23, 2007, 3:28 PM - Re: Anyone ever done a vac-Formed Helmet? #39

    That turned out really good!
  15. CGClone's Avatar
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    Aug 23, 2007, 3:34 PM - Re: Anyone ever done a vac-Formed Helmet? #40

    BradleyFett are you going to make a completely clean version with no borden connector mole on the cheek?
  16. Sixxgunn13's Avatar
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    Aug 23, 2007, 3:47 PM - Re: Anyone ever done a vac-Formed Helmet? #41

    You sir, Are the Vac form king!!
  17. I helped at SDCC '08 MandalorFett's Avatar
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    Aug 23, 2007, 4:07 PM - Re: Anyone ever done a vac-Formed Helmet? #42

    Wow, that's very cool.
  18. Member Since
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    Aug 23, 2007, 4:09 PM - Re: Anyone ever done a vac-Formed Helmet? #43

    Quote CGClone said: View Post
    BradleyFett are you going to make a completely clean version with no borden connector mole on the cheek?
    That's a good question- I can do it either way. I suppose it might be better to leave that little detail off and perhaps do it as a resin part. What does everyone think?

    Mark
  19. tubachris85x's Avatar
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    Aug 23, 2007, 4:10 PM - Re: Anyone ever done a vac-Formed Helmet? #44

    Hmm.. I am also in the process of making a vac-formed mando bucket. Nice work.
  20. tubachris85x's Avatar
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    Aug 23, 2007, 4:12 PM - Re: Anyone ever done a vac-Formed Helmet? #45

    You did a single mold cast? Or is it two part?
  21. Member Since
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    Aug 23, 2007, 4:12 PM - Re: Anyone ever done a vac-Formed Helmet? #46

    Quote MandalorFett said: View Post
    Wow, that's very cool.
    Thank you.

    But I prefer 'Steely-Eyed Missile Man'. :P



    BTW, I just vac'd a new faceplate with the visor surface built in.
    Pics:






    Mark
    Last edited by Bradleyfett; Aug 23, 2007 at 4:27 PM.
  22. Member Since
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    Aug 23, 2007, 4:15 PM - Re: Anyone ever done a vac-Formed Helmet? #47

    Quote tubachris85x said: View Post
    You did a single mold cast? Or is it two part?
    Actually, 3 parts- front, back, and crown. The crown will be long enough to fit just inside the top edge of the front/back. The seams are mostly under the resin ear pieces.

    Mark
  23. Member Since
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    Aug 23, 2007, 4:17 PM - Re: Anyone ever done a vac-Formed Helmet? #48

    Quote tubachris85x said: View Post
    Hmm.. I am also in the process of making a vac-formed mando bucket. Nice work.
    Thanks- yep, this helmet really looks good in vacuform- better than I thought it would. Good luck with yours as well!

    Mark
  24. Member Since
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    Aug 23, 2007, 5:01 PM - Re: Anyone ever done a vac-Formed Helmet? #49

    Looks like I won't need to do as many pulls per helmet-

    So I can do these for less- probably closer to $60. I'm going to call it $75 shipped (US or Canada). $65 for each additional helmet shipped in the same box.

    Mark
  25. DutchFett's Avatar
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    Aug 23, 2007, 5:10 PM - Re: Anyone ever done a vac-Formed Helmet? #50

    Awesome work!
    Last edited by DutchFett; Aug 23, 2007 at 5:11 PM. Reason: misspelled

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