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  1. samlynn79's Avatar
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    Nov 25, 2007, 4:38 PM - Attempted BF bucket using WOF plans #1

    I stumbled across this forum last weekend somehow while browsing the http://www.instructables.com website. I've been reading thread after thread, looking at all these amazing helmets, and I really wanted to try one of my own. I downloaded the WOF templates, went to the local hardware store, and picked up some supplies.
    This morning, I cut out all the WOF templates, but I realized that in the course of reading all the threads, I never actually found specific directions on how to assemble the actual bucket. Taking a chance, I just glued the paper templates to the 18"x24" "For Sale" signs that I bought at the hardware store, and cut them all out carefully with scissors. I realized way too late - actually, when I was looking at all the individual pieces that I'd spent 2 hours cutting out, that I should have laid all the bucket templates in a row on one solid piece of plastic, rather than trying to glue them all together.
    Also, using "Amazing Goop" as an adhesive to glue the templates to the plastic was a bad idea. When I heated it up in the oven, the paper wrinkled awfully, and the goop went runny.
    Here are some pictures of the whole mess.





    Do you guys have some tips on this part? Also, I haven't been able to find the WOF template for the dome. Anyone have that? Help is appreciated!
    Once I've got it all put together, I've got bondo and sandpaper for the smoothing process.

    Some quick background on me:
    I'm 28, and I'm a US Marine stationed in 29 Palms, Ca. I'm married, no kids. Home is in Albany, NY, where I'll be returning to go to school for Radiologic Technology when my enlistment contract is over next summer.

    Thanks!

    ~Sam
    Last edited by samlynn79; Nov 26, 2007 at 11:08 AM.
  2. Gypsyboy's Avatar
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    Nov 25, 2007, 5:25 PM - Re: Attempted BF bucket using WOF plans #2

    Looks like a good start, but it looks like you might have a problem with the seam above the cheekbone... maybe, too early to tell for sure. Do you have clamps? They will go a long way toward helping you keep things togther and pressing lamination into place.

    For plastic, try using cyanoacrylate (super glue).
  3. Jaiden's Avatar
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    Nov 25, 2007, 9:30 PM - Re: Attempted BF bucket using WOF plans #3

    Welcome to the boards!

    The dome templates should be in the same thread where you got the others.

    My best advice is to take your time. Don't get to ahead of yourself and it will all work out fine in the end. There are a lot of great SB bucket threads, each with their own tips and tricks.

    Good luck!

    David.
  4. samlynn79's Avatar
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    Nov 25, 2007, 10:41 PM - Re: Attempted BF bucket using WOF plans #4

    Man, I am having the hardest time trying to get the cheekbone pieces to fit right. I understand that there's going to be some messing with it, but I'm just not seeing how they're supposed to be adhered to the helmet. Some kind of bracing from behind? I tried making some tabs of the same material, with a small measure of success, but I'm just not satisfied with the result. Too many gaps between the curves.
    Tomorrow I'm going to find a longer piece of material, print some more templates, and cut the whole thing out of one piece. I've no doubt that will be much easier to work with. Perhaps find an easier way to get the template off the plastic once I'm done with it too, that was a nasty mess. :-P
  5. Jaiden's Avatar
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    Nov 26, 2007, 4:40 AM - Re: Attempted BF bucket using WOF plans #5

    IMHO, Digifett has one of the best detailed builds lately. Check out his thread for some very useful tips. I did, and here's my result.

    In Digifett's thread, check out Post #27 specifically for the cheek build.

    David.
  6. Jango72's Avatar
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    Nov 26, 2007, 5:17 AM - Re: Attempted BF bucket using WOF plans #6

    You've got a decent start there, and it looks workable still, so don't fret too much.

    For working the cheeks, here's the method that I used in my builds...

    1. Attach the curved piece of the cheekbone to the edge closest to the ear first, and line up the assembled flat portion of the cheekbone and glue it along the bottom edge only. Then slowly work the upper cheek into place as you move your way towards the front edge of the mandibles. I found that hot glue works best for attaching the cheeks.

    2. Once you've got the curved parts of the cheeks installed, now carefully glue the flat portion of the cheekbone to the curved portion.

    It takes a bit of fiddling during this entire process, so take your time and ensure that you're relaxed and calm as can be.

    Jango72s helmet builds.
  7. samlynn79's Avatar
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    Nov 26, 2007, 10:54 AM - Re: Attempted BF bucket using WOF plans #7

    Man, that's exactly the kind of direction I needed. Hot glue, huh? I'll try that. After work today I'll pick up some more material and a hot glue gun and give it a shot. If that doesn't work as well as I'd like, I'll try the option of separating the curved cheekbone into a few pieces. And gluestick! That's perfect! I should be able to just peel the paper straight off the plastic after I cut it out. That was my biggest problem on the last one... the paper wouldn't come off. I've also got to stop by Home Depot, or maybe the local hardware store, and pick up some of those clamps. Those things would definitely be handy right now!

    Oh, also, another question. The templates labeled "Inner Surface". How exactly do those fit into the picture? When I cut them out on this one, I just noticed that they fit on the inside of the main templates, leaving just a little room around the top, bottom, and edges. I haven't seen any instructions mentioning these, but I'm assuming this is to leave a lip around the inside, similar to the cheekbone, to make it easier to adhere the main body form, or a forming ring around the top and bottom. The problem that I ran into with this, in "installing" the inner surface pieces before the "cooking" step, was that when it was bent into its shape after I let the adhesive cure for a bit, when I managed to peel some of the paper off after I cooked it, the whole outer surface had a dimpled, rippled effect (visible on the paper surounding the bucket) due to what I'm assuming was a slight shrinking of the plastic in the heat. Would it be better to form the inner and outer surfaces first, then fit the one inside the other?

    I'm excited about building this helmet. :-P I've got a buddy back home in New York that's an even bigger Star Wars fan than me, he'll blow a fuse when I show it to him.

    I'll take more pictures this afternoon of what progress I've made.

    Thanks guys,
    ~Sam
    Last edited by samlynn79; Nov 26, 2007 at 11:15 AM.
  8. Jango72's Avatar
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    Nov 26, 2007, 11:37 AM - Re: Attempted BF bucket using WOF plans #8

    In regards to the inner surface question, there are a few of us that simply didn't use the inner surface templates. Instead, we used two of the outer surface templates ( the one used for the inner with the seam in the front, and the one for the outer with the seam in the back ) to create the main shell.</p>

    I myself didn't actually cook my helmet either. I kept it clamped until the glue dried and it held its shape. ( that's for the plastic one I made as cooking isn't needed for the cardboard versions. )
  9. samlynn79's Avatar
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    Nov 27, 2007, 1:07 AM - Re: Attempted BF bucket using WOF plans #9

    That's a really good idea. I'll definitely do that tomorrow when I attempt the bucket again. In the meantime, I got the dome assembled today. Turned out pretty good, altho not exactly as I thought it would. I tried to wrap the dome templates around the cardboard dome I made from those templates, but the dome shell pieces came almost 2 full inches short of reaching around. I had to assemble them off the shaping template, which actually still turned out really well. Here's some pictures I took during the process.















    After assembling everything with tape on the outside, superglueing some tabs to hold the edges together on the inside, I ran a bead of latex goop down all the seams. I did the front left half after I got home from work, and I finished gooping it before my wife and I went out to the base theater to watch Good Luck Chuck - hilarious movie, by the way - and did the rest of it when I got home. It will cure completely by tomorrow morning.
    My wife's going to pick up a hot glue gun and some glue sticks tomorrow while I'm at work, so I can start work on the bucket afterwards. I'll keep your ideas in mind! I'm sure this one will turn out much better.
  10. Jaiden's Avatar
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    Nov 27, 2007, 3:49 AM - Re: Attempted BF bucket using WOF plans #10

    Great work on the dome! I wish I'd have thought of the latex goop step.

    David.
  11. Stinkape fett's Avatar
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    Nov 27, 2007, 9:02 AM - Re: Attempted BF bucket using WOF plans #11

    I did the same thing with cutting all the parts our, the first time. I used it as a pratice piece, then I made a one piece like you mentioned much easier to work with, also Little clamps make much easier. Good luck..

  12. samlynn79's Avatar
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    Nov 28, 2007, 1:02 AM - Re: Attempted BF bucket using WOF plans #12

    Well, I didn't get started on the bucket yet, but I did continue my work on the dome by applying the first of at least five layers of vinyl spackling. Great stuff, vinyl spackling. Doesn't flake, crack, or peel, and it's completely sandable, and extremely durable. Takes a few hours to set, at least 5 if you want to sand it. I'm going to let it set over night. The edges can be trimmed off with a knife, as there will be some settling of the vinyl to the bottom overnight.






    I'll probably sand it and add another coat when I get home from work tomorrow, and while that's curing, I hope to start on the bucket. Depends on how clingy my wife is feeling. :-P

    If you guys have any tips to add, please send any and all, as this is my first project from scratch that I've ever attempted.
  13. Gypsyboy's Avatar
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    Nov 28, 2007, 7:22 AM - Re: Attempted BF bucket using WOF plans #13

    "Vinyl spackling"? I didn't know they sold such a thing. I will have to look for the stuff. Is it comparable in price to the regular type of spackling?
  14. samlynn79's Avatar
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    Nov 28, 2007, 8:10 AM - Re: Attempted BF bucket using WOF plans #14

    The pint I bought cost $2.29 at the hardware store down the street.
  15. samlynn79's Avatar
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    Nov 28, 2007, 7:57 PM - Re: Attempted BF bucket using WOF plans #15

    Ok, so the spackling isn't turning out to be as durable as I would have hoped in this application. The dome itself is certainly more rigid, but the spackling keeps cracking off the bottom edge when I try to sand there. Does Bondo do the same thing, or is there a trick to stiffening up the bottom edge to keep it from flexing?
  16. Jaiden's Avatar
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    Nov 28, 2007, 9:54 PM - Re: Attempted BF bucket using WOF plans #16

    I covered my bucket with a layer of fiberglass first. This gave me the rigidity I needed to get good results from the bondo. The only place I'm having a problem with is on the back right below the keyhole section, but this is only because I didn't make sure the fiberglass was secure to the plastic before leaving it to dry. It didn't hold properly, chipped of, and now the Bondo doesn't like to stay stuck to the plastic.

    I'd say try the fiberglass mat or cloth and see how it works out for you.

    David.
  17. samlynn79's Avatar
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    Nov 28, 2007, 10:39 PM - Re: Attempted BF bucket using WOF plans #17

    I've never worked with fiberglass before, but I've seen it used to make custom formed speaker enclosures on TV. I'll give it a shot.
    I just ruined my second attempt on the bucket. God hates me. I didn't glue the paper to the plastic this time, and I sealed the seams together with a sandwich of two strips of plastic and super glue, which turned out awesome. I decided to heat this single-layer bucket for a minute or two in the oven on 200 so it would hold its form nicely, and when I pulled it out, the entire top edge - including the half-circle right ear - was curling over like a dead leaf. Fortunately, I still have a few hours left to the evening, and enough plastic to make another attempt. Onward!
  18. samlynn79's Avatar
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    Nov 29, 2007, 1:26 AM - Re: Attempted BF bucket using WOF plans #18

    Ok. After several hours, most of it spent monkeying around with the right cheekbone - my God, how do you guys do it - I'm satisfied with my progress. A non-melted bucket, one cheekbone installed. The hot-glue was a challenge... was almost too hot, the plastic was getting real soft. I can cover those areas later tho. Thanks for the ideas, guys.

  19. I helped at SDCC '08 GCNgamer128's Avatar
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    Nov 29, 2007, 4:17 AM - Re: Attempted BF bucket using WOF plans #19

    Looking much better
  20. Jaiden's Avatar
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    Nov 29, 2007, 5:54 PM - Re: Attempted BF bucket using WOF plans #20

    Agreed. Much nicer now.

    Steady as she goes, soldier.

    David.
  21. samlynn79's Avatar
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    Nov 30, 2007, 3:33 AM - Re: Attempted BF bucket using WOF plans #21

    Made alot of progress tonight. Chipped all the latex plaster off the dome, completed the cheeks, made new inner bracing rings from the templates, and put in a temporary visor made from an old welding helmet from work. There's some smoothing up to do, but I'm bringing the helmet to work tomorrow. I've got a buddy there that's got experience with fiberglass and bondo. Hopefully, some magic will happen.

  22. Stormrider's Avatar
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    Nov 30, 2007, 10:14 AM - Re: Attempted BF bucket using WOF plans #22

    Im not sure, but it looks like you may have left the extra border on the dome pieces (the base) it looks on teh templates like it stays attached, when in fact it needs to be cut off. Its like a half an inch worth of material. Otherwise, your cheeks look excelent.
  23. Jango72's Avatar
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    Nov 30, 2007, 10:47 AM - Re: Attempted BF bucket using WOF plans #23

    I found that you'll need to remove 1.5cm of material from the bottom edge of the dome, when making it at 100%.
  24. samlynn79's Avatar
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    Nov 30, 2007, 5:48 PM - Re: Attempted BF bucket using WOF plans #24

    Oh man... I wish I'd known that before I took my helmet to work today and fiberglassed the hell out of it. I spent about seven hours glassing, sanding, glassing, sanding, glassing, sanding... all the power sanders were locked up too, so I did it all by hand. Here's pictures.








    Even with the mistake with the dome template, I think it turned out really well. I thought that extra strip on the bottom was supposed to make it easier to wrap around the template. Blast. :-P
    I was going to glass the whole thing, but after just starting with the dome, the glass is so difficult to work with, that I decided that I'll use bondo on the face. The fiberglass is so solid that I may reinforce the mandibles from the inside using fiberglass around the cheekbones.
  25. samlynn79's Avatar
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    Nov 30, 2007, 11:36 PM - Re: Attempted BF bucket using WOF plans #25

    Ok. So I spent the evening doing ALOT of sanding. I've done as much as I can with the fiberglass, so I put a coat of sandable primer on. Tomorrow my wife is taking me out for my birthday, so on Sunday I hope to finish the sanding, and put on the outer plastic piece that wraps around the visor, and has the template for the ear pieces, wrapping around the back. I'll probably use bondo to finish the cheeks and cheekbones once that's in place. I'm not sure what I'm going to do about the vent slots in the back yet. The fiberglass layer back there is pretty thin, so I don't think I should have a problem cutting through it, probably have to use a saw.
    I still don't know what I'm going to use for the RF stalk, tho... tossing around ideas of balsa wood, but that's too flexible. Plastic might be more sturdy, but I also still have plenty of fiberglass, too.... maybe make a mold with plastic, and cast it in glass.
    Ideas, ideas. It's hard to sleep at night with all the ideas and plans and possibilities running through my head.

    Last edited by samlynn79; Dec 1, 2007 at 12:15 AM.

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