Page 1 of 2 12 LastLast
Subscribe
  1. BH2372's Avatar
    Member Since
    Sep 2002
    Posts
    366
    Jul 7, 2004, 12:46 PM - Merged: cutting out keyholes !!! #1

    hey guys and galls ,

    how in the world do you cut out the key holes on a fiberglass helmet without screwing up ?do i just need to get a really small dremel bit ?
  2. Member Since
    Nov 2003
    Posts
    458
    Jul 7, 2004, 2:53 PM - Merged: Re: cutting out keyholes !!! #2

    I used a small carbide engraving tip. I did the rough cuts with that and then hobby files to smooth it out. Hod the bucket and dremel steady. I would use a flex shaft if you have it.

    The bit looks like:



    Loranar
  3. Lynn TXP 0369's Avatar
    Member Since
    Mar 2002
    Posts
    1,785
    Jul 7, 2004, 6:05 PM - Merged: Re: cutting out keyholes !!! #3

    Drill a bunch of tiny holes close together in the key holes than take a small needle file and open them up.
    HTH,
    Lynn
  4. Nobody's Avatar
    Member Since
    Apr 2004
    Posts
    146
    Jul 7, 2004, 8:18 PM - Merged: Re: cutting out keyholes !!! #4

    I used the drill and file method and it worked great.
  5. Member Since
    Dec 2003
    Posts
    296
    Jul 7, 2004, 9:59 PM - Merged: Re: cutting out keyholes !!! #5


    Same here. I used the largest drill bit that didn't go
    beyond the edges I wanted cut out. Then I went to
    work with a file to finish shaping the openings. Take
    your time with the file and give it a nice, clean edge.
  6. Member Since
    Apr 2004
    Posts
    19
    Jul 8, 2004, 5:56 AM - Merged: Re: cutting out keyholes !!! #6

    I used an exacto knife, and I do not recommend them. Ill have to file the litle corners down now due to not being able to cut clean with it. Next helm its dremal all the way
  7. Member Since
    Nov 2002
    Posts
    49
    Nov 7, 2004, 8:19 PM - best way to remove back vents? #7

    I'm getting ready to cut the vent holes out of my kid's fiberglass helmet. It's a beautiful juddz dwedd special and I'm a bit nervous about damaging it.

    Any ideas as to the best way to tackle them? Does dremel make a good tool for this or should I just take the time to cut them out with an exacto knife?

  8. Member Since
    Jul 2003
    Posts
    99
    Nov 7, 2004, 8:45 PM - Re: best way to remove back vents? #8

    Dremel,xacto and small file.
    Start with the dremel make a hole in
    center of each vent and then use xacto to trim more of plastic away and then to the small file to square off the edges of each vent.
    Thats how i did it on my personal Fett helmet:-)
  9. jawafive's Avatar
    Member Since
    Oct 2002
    Posts
    538
    Nov 7, 2004, 8:51 PM - Re: best way to remove back vents? #9

    I wouldn't even worry about it personally. I doubt I do that when I get my fiberglass helmet. I've trimmed those keyslots out 3 times and hated every second of it.

    -Matt
  10. Member Since
    Nov 2002
    Posts
    49
    Nov 7, 2004, 9:43 PM - Re: best way to remove back vents? #10

    Wait until you get your FB helmet, jawafive. A nice one is so delectable that you'll want to do everything you can to make it look great. I didn't do this for the last helmet, though, so I guess I'm not burned out yet! Probably will be after these vents are finished.

    Thanks for the advice, Yautja! I'm definitely going to do use the dremel/exacto/file method...when I'm very sober and alert!
  11. BobaFettish's Avatar
    Member Since
    Mar 2002
    Posts
    3,228
    Nov 7, 2004, 10:19 PM - Re: best way to remove back vents? #11

    Two words: needle files. You can normally get a set of them for under $10. Take your time as a little goes a long way when trimming tiny details like this. It is better to undercut them all first and then go back to widen them than to overcut the first one and then have to do the same to the rest to even them out.
  12. FettTheHunter's Avatar
    Member Since
    Jul 2004
    Posts
    405
    Nov 7, 2004, 11:00 PM - Re: best way to remove back vents? #12

    So you are supposed to cut them out !!!.. I was'nt sure about that

  13. Member Since
    Nov 2002
    Posts
    49
    Nov 7, 2004, 11:05 PM - Re: best way to remove back vents? #13

    Needle files? What kind of store/department would sell these?Maybe in an arts and crafts section of Wally World? They sound like a good idea. I was thinking of using one of those cheap, really thin fingernail files, but that won't help with smoothing out the protruding divot.
  14. Member Since
    Nov 2002
    Posts
    49
    Nov 7, 2004, 11:14 PM - Re: best way to remove back vents? #14

    Quote:So you are supposed to cut them out !!!.. I was'nt sure about that
    You can cut them out and buy a $100 20 year old Casio MQ-1 calculator, butcher it, and put the circuit board behind there for accuracy. Remember, FettTheHunter, at all cost this costume should NEVER end!! It's NEVER finished!!! (running down the street, ripping my clothes off!)

  15. FettTheHunter's Avatar
    Member Since
    Jul 2004
    Posts
    405
    Nov 7, 2004, 11:31 PM - Re: best way to remove back vents? #15

    I think I'll find a alternative to the casio MQ-1 calculator chip... or make a copy of it 8)

    Your not wrong about a Boba Fett costume never being truly finished

  16. DarthBish's Avatar
    Member Since
    Jun 2002
    Posts
    262
    Nov 8, 2004, 7:03 AM - Re: best way to remove back vents? #16

    I just went to the local computer shop, got a couple of old cards that were broken, and picked the one that I thought looked the best stuck behind the vents. No one will ever notice that it's not from a Casio.
    As for cutting out the vents.......Dremel, Dremel, oh & Dremel.
    It's never easy making that first step to cut something out of a helmet..(or anything for that matter)..Indecision and uncertainty are the bane of the Fett maker, but once you do it you'll wonder what all the worry was about.
  17. carbonitekid's Avatar
    Member Since
    Mar 2004
    Posts
    499
    Nov 8, 2004, 7:37 AM - Re: best way to remove back vents? #17

    For those of us going the ventilation route, what is everyone using for the wire mesh behind the keyslots?
  18. FettTheHunter's Avatar
    Member Since
    Jul 2004
    Posts
    405
    Nov 10, 2004, 11:39 PM - Re: best way to remove back vents? #18

    I got my needle files today ... now all I need is my helmet



  19. cal196's Avatar
    Member Since
    Aug 2004
    Posts
    2,617
    Nov 11, 2004, 11:42 AM - Re: best way to remove back vents? #19

    heat gun and an exacto knive. dunno if its the best way.
  20. Member Since
    Jul 2003
    Posts
    99
    Nov 11, 2004, 2:16 PM - Re: best way to remove back vents? #20

    I used the flexible black screen stuff for like screen porches or doors on my Trooper and Fett helmets. It comes in little patch kits or a big roll. I just bought the roll so i would have some whenever i needed it. If anyone needs some just PM me and i'll send it out to ya for nothin.
  21. carbonitekid's Avatar
    Member Since
    Mar 2004
    Posts
    499
    Nov 12, 2004, 5:17 AM - Re: best way to remove back vents? #21


    Yautja wrote:

    I used the flexible black screen stuff for like screen porches or doors on my Trooper and Fett helmets. It comes in little patch kits or a big roll. I just bought the roll so i would have some whenever i needed it. If anyone needs some just PM me and i'll send it out to ya for nothin.
    Thanks for the info, I might take you up on your offer.
  22. Member Since
    Mar 2004
    Posts
    149
    Nov 12, 2004, 7:00 PM - Re: best way to remove back vents? #22

    After making 30 or 40 f/g lids,gotta be dremel and needle files.
    Bloody tedious,but best result,for sure.
    I cut out the slots on my son's spare dp97 tha same way,but an exacto and needle files will suffice.
    WEAR A MASK!
  23. Member Since
    Nov 2002
    Posts
    49
    Nov 15, 2004, 6:23 PM - Re: best way to remove back vents? #23

    I bought a nice set of needle files ($16.97 at Home Depot -- the only set they had, actually!) and after a few rainy afternoons filing away, I finally have a beautiful set of keyholes! I ended up drilling holes along the vent line and then filing away on either side of them until they were gone. It wasn't fast but I think you guys are definitely right -- slow and steady wins the race when taking out the keyholes properly.
  24. Member Since
    Mar 2004
    Posts
    149
    Nov 21, 2004, 3:59 AM - Re: best way to remove back vents? #24

    Well done Mercutio.........
    I'm proud of you,son..........
    Every little bit you do yourself,gives you skills you might need later on in your costume making.
    As a guy who makes fett items for others,I love to see guys like you,who 'do it themselves'.
    all the best..........jon.......
  25. Member Since
    Nov 2002
    Posts
    49
    Dec 1, 2004, 8:21 PM - Re: best way to remove back vents? #25

    Thanks, Oz! Slowly but surely this costume will be completed!And when it's finally (well, not finished...let go!) I will owe it all to awesome TDHers like you on this board whose suggestions, feedback, talent and enthusiasm keep me going! I may need a support group and counseling to get me through the gloves, though!

Similar Threads

  1. ESB Helmet Vents / Cuircuit Board Knobs
    By Skaught in forum Boba Fett Helmet
    Replies: 12
    Last Post: Jul 8, 2009, 3:16 PM
  2. Back Vents - Should they go?
    By Nocturne in forum Boba Fett Helmet
    Replies: 3
    Last Post: Aug 5, 2006, 4:07 PM
  3. How do you remove RF on rubies
    By Jangos_son in forum Boba Fett Helmet
    Replies: 2
    Last Post: Apr 3, 2006, 8:08 PM
  4. How do I remove the t-visor from a DP 95?
    By jodo in forum Boba Fett Helmet
    Replies: 16
    Last Post: Feb 8, 2005, 11:23 PM
  5. Remove paint
    By Karate-Jedi in forum Boba Fett Helmet
    Replies: 5
    Last Post: Apr 14, 2004, 2:40 PM