Brak's Buddy's Fett Helmet Project

A good friend of mine who I will not name (and I would prefer you didn't name in this thread) was kind enough to send me a helmet to try my hand at. I have never really worked on a project as most of the props and pieces I have acquired are found parts so this has been quite the challenge. I am nearing completion and just couldn't wait to post pics.

The helmet is all fiberglass with a white gelcoat. when it arrived the entire visor section was solid so I colored it in with a marker, then quickly hotglued the ears and rangefinder in place just to get an overall feel for how the completed helmet might look. Here is the result:



I began the project by grinding down the raw bottom edge of the helmet and cutting out the visor section. Once the visor was removed I realized there were going to be some HUGE issues with sanding the visor lip and making it smooth. It is almost impossible to reach the inside of the horizontal slot of the visor with a dremel or sandpaper. Also I realized that some parts of the visor area were going to have to be built up with bondo, something I had never used before. Well, after MUCH bondoing and MUCh dremel work and more sanding than I even want to remember I am pretty much satisfied with the visor area. It isn't perfect but it is as close as I think I can get it.

At this stage I only have the cheeks and keyhole area to rework and I will be ready for my first coat of primer!

Here is the current state of the helmet:



Here are a couple of pics of the visor area so you can get an idea of what I have been doing. It doesn't look like much but it was a HUGE pain!

Lookin' good Braks.

I was kind of hoping that there wouldn't have to be that much work on the helmet . . I've never done any of that stuff either , but, looks like you've done a great job on smoothing it out.

Having not seen the gelcoat yet . . . what's it going to be like for painting? Are you going to have to sand him first, or do you think the primer will stick to it?

Jer

Ego wrote:Lookin' good Braks.

I was kind of hoping that there wouldn't have to be that much work on the helmet . .

. . . what's it going to be like for painting? Are you going to have to sand him first, or do you think the primer will stick to it?

Jer

Honestly there isn't that much work that HAS to be done. There are only three things that are absolutely essential.

1. Clean up the raw edges at the bottom of the helmet. Very quick and easy. Nothing to it.

2. Cut out the visor section. Again, VERY easy with a dremel and a cutting disc. Now, I went all out and bondoed the area back up quite a bit and tried to get it all perfectly smooth. If you are really good with a dremel and don't mind a bit of inconsistency that no one will ever see anyway it isn't a big deal.

3. Sand done the seam that crosses the dome. No biggie here either.

As far as sanding goes, it wouldn't hurt to give the entire helmet a once over but I imagine paint would stick to the raw gelcoat.

I would like to state that this helmet is beautiful and I am VERY happy with it. I am putting a ton of work into it but it is not because my friend didn't make a quality helmet. I am just trying to make it as perfect as possible. I love this helmet and I don't want to rush it.

Not to nit-pick because I usually don't but...

Is it me or is the top part of the visor area kind of wavy? It seems that it's not completely even. Could just be the pictures too. Otherwise, that kicks!

Good eye webchief. You are absolutely correct. It is not straight and it was sculpted that way very specifically to match the real helmet! My friend went all out with this and tried to add EVERY detail!!! Remember it is the assymetrical aspects of the Star Wars helmets that make them unique and cool. DP utterly ruined their Fett helmets by trying to clean them up and make them all symetrical. My friend did not want to make the same mistake.

webchief wrote:Not to nit-pick because I usually don't but...

Is it me or is the top part of the visor area kind of wavy? It seems that it's not completely even. Could just be the pictures too. Otherwise, that kicks!

Wow... very cool then. I had no idea the original was like that. That's why your the man Braks!

P.S. off topic for a second, I noticed you said you were a big Pearl Jam fan... ME TOO! Best band in my opinion.

O.K.... back to the helmet... Someday I'll turn in my 96 Don Post re-paint for a fiberglass one...someday...

Glad to hear it's not as much work . . . and I was expecting the seam and the edges at the bottom . . . . but, what do you think of doing this for the visor.

I was planning on not cutting it out flush to the line where it should be cut, but leave a bit there, then sand it down to where it should actually go . . . wouldn't that be easier than trying to cut it exact and then bondoing back up?

THis is great, you'll be a couple of weeks ahead of me . . I can learn! hehe

Jer

That helmet looks great, i don't mind a little work myself, its all part of the fun
I can't see much filler around the lip of the visor area, did you use white filler or something?

Keith.

Lookin' good BB! That's going to be one FINE helmet when you're done! Kudos to your sculptin' buddy too!

WOW!! That looks really great Braks! You should be proud! I don't have a fiberglass helmet (not yet) , but I did make my own gauntlets out of fiberglass. Even a perfect original, with a perfect mold, perfectly cast will need some finishing. Making the helmet flush to the visor right out of the mold is impossible. The outside of any fiberglass piece is all smooth and pretty, but the other side will have some variation in thickness of both the gelcoat and the layers of fiberglass. A few layers of bondo and sanding will fix it right up. The gelcoat is very tough and needs to be sanded down with a course, then medium, and finally fine grit sandpaper before primed. This will make the surface perfect for wetsanding and then painting.

Ego wrote:I was planning on not cutting it out flush to the line where it should be cut, but leave a bit there, then sand it down to where it should actually go . . . wouldn't that be easier than trying to cut it exact and then bondoing back up?

I think you will see what I mean when you get a fiberglass helmet. As is mentioned above, the thickness of the fiberglass isn't consistent so the inside edge, the edge that the visor sits on, isn't consistent no matter how you cut out the visor area. If you want a smooth edge on the inside you will HAVE to bondo it somewhat. No big deal except for the fact that the visor is so difficult to get to from the inside. I HIGHLY recommend getting a set of large and small files. This made work SO much easier. if I had to rely on sandpaper alone I would have killed myself long ago. Files rule because they are fast working on large areas and they are good for straight level lines. A dremel is good too but it is very easy to screw things up with a dremel but you have a great deal of control over a file.

Yeap, I'll second that. Unless you are a dremmel master, you're bound to get an inconsistent line. I had a much easier time getting things level and sanded after I gave it a shot with some files. Of course that was on a standard DP, I'm not sure I would trust myself with one of those, lol.

Great work, BB. That puppy is going to look smmoooooooth.

BB.... Great helmet!! Did you use just the straight Dremal as is with just the attachment bits or did you use a flex shaft adaptor and bits on your inside the visor area?

I tried using my Dremal plain with just the bits and it was almost impossibly it get inside of my mystery helmet, I then used my flex shaft adaptor and it made all the difference in the world, I was able to get in tight around the inside visor area and sand it all to a smooth an even thickness, using the Dremal sanding tubes, and I used no Bondo or putty what so ever.
Just a thought, I plan on doing that when my new helmet arrives as well.

Haven't gotten a flex shaft yet. Perhaps I need to! My dremel frightens me. It is just so fast and cuts so quick and takes off a ton of material before you know it. Again, this is my first time really using it though so I am getting better...

BB & TD . . . I misunderstood what edge we were talking about so . . never mind, yeah, that makes a lot more sense now that I know what you're talking about.

Good idea on the flex shaft, I'm thinking I might pick one up as well . . . trying to get my tools ready for when the helmet arrives.

And good idea on the file too . . . I can see that helping a lot on this project. Using flat files I take it??

Jer

Boy, the flex shaft is like night and day on a Dremel. Ive been sharpening up my RA gauntlets using a dremel, and I didn't even realize the diffrence until last night. After grinding with the Dremel in my hands, my hands feel sore and strange from all the vibrations. But with the flex shaft, there is a lot less vibration and it's a lot easier to control the tool end. Grab one brak, it really does make a difference.

WOW!!

That is superb work Braks.

Youve got to but a flexi shaft, Dremels shouldnt be sold without them. They really are that good.

Nathan

Keith wrote:That helmet looks great, i don't mind a little work myself, its all part of the fun
I can't see much filler around the lip of the visor area, did you use white filler or something?

Keith.

Actually, there isn't much filler ther but I had to do it over and over and over to get the little bits in just the right places to get the visor to sit as flush and smoothly as it need to be. Actually, the visor does not sit flush against the helmet in all areas on the real deal nor does it on mine. The edges of the mandibles flare away from the visor and if you look at the helmet from the side you can see where the mandaibles pull away

Ego wrote:And good idea on the file too . . . I can see that helping a lot on this project. Using flat files I take it??

I bought my files from Lowes

1 Nicholson 8" Flat Bastard File for large work

1 Nicholson 6 Piece 4" File Set with Handles for medium to fine work

1 Nicholson 5 1/2" Hobby File Assortment Set for really small places

WOW THAT LOOKS FANTASTIC!!!


Two paws up to ya.

Bear

Looks sweet. (I can't stop saying 'sweet', it's really annoying me).

Nice and smooth, and excellent start to your first project

When mine arrives I'm not so worried about the prep, but I'm soo scared that I'll botch the paint job. This helmet deserves so much better than I can give it lol

Looks great, I'd love to see constant updates. I'm very anxious to see one of these painted

Phil

bb how thick is the visor? is it pre shaped or flat?

i'm doing a dp at the moment(until my one arrives) and can't quite seem to get the visor to curve properly,especially at the bottom edge

cheers

chris

journeymanprotector wrote:When mine arrives I'm not so worried about the prep, but I'm soo scared that I'll botch the paint job. This helmet deserves so much better than I can give it lol

I wasn't worrying about that yet for when mine arrives but . . . thanks JMP . . . thanks for giving me one more worry about screwing up this helmet! hahahaha

BB . . thanks for the advice on the files . . . always looking for a good excuse to hit Canadian Tire and buy more tools!

Jer

Veeeeeeery nice Braks !

Can't wait to see the ears and a basecoat on that baby !

No problem Ego,
I like to try and spread around a bit of insecurity, that way I'm not the only person who feels intimidated about making these costumes

Best luck
Phil

tremorboy2000 wrote:bb how thick is the visor? is it pre shaped or flat?

The visor appears just a bit thinner than the real deal to me and although it does have a bit of curve it doesn't have quite enough. The best way I have found to shape it is to heat it slightly (SLIGHTLY!!!!) over the stove then wrap it around something VERY smooth and round like a 1 gallon paint can.

After finally seeing it, I'm very nervous about the whole thing!! :puke Is anybody out there willing to help me out on the fiberglass clean up work?? Haven't ever worked with the stuff and would hate for this to be the first trial and error project!! Have only worked with plastic materials and I don't trust myself on this one!!

Humm....That is a great lookin can ya got there Braks. Sanding, well, to get into those tight spots, you can always use an emery board, the type you use to file nails. Or a paint stirer with a piece of sand paper wraped around it. If you do a lot of sanding of the fiberglass, (before you prime where you are only removing a little amount of material) I would use a sandpaper that can be used wet. Sand the helmet wet so that the fiberglass glass fibers don't become air bourn. You breathe in those things and it aint a good idea

Dude, I know exactly how you feel. I was in the same boat as you! I have never even successfully pt a model together, much less something of this magnitude! It was extremely daunting at first but as you go along it gets easier and easier. I will stress this, WEAR A FREAKIN' MASK AND EYE PROTECTION! It also wouldn't hurt to wear gloves if you don't want to be itching all night.

I would also recommend that if you are not familiar with a dremel as I am/was not, ONLY use it for the rough work. Use files or sandpaper for the detail work. You have a LOT more control over them and are a lot less likely to screw something up. So far I have use 100, 150, 220 and 600 grit sandpaper.

The way I did the bondo was in VERY small batches with VERY little catalyst. I would but just a touch, not even a big drop, of cataclyst on a paper plate then dip my finger into the bondo and get out a good sized glob to mix with the catalyst. Worked wonders. the first time I tried to use bondo I used WAY too much catalyst and it began to gel in like 5 secs.

Once you have worked with the bondo a bit you will see that although it might be a pain there is really no way to screw up the helmet to a point in which the bondo couldn't fix, expect maybe if you used a chainsaw.

You have probably heard it a million times but patience is the key. When you start to get frustrated just set the helmet down and come back to it later. Also keep in mind that you will be well rewarded in the end for every minute you spend prepping. Don't rush it! Take your time or you WILL be sorry.

Heh heh.... here I am writing advice like a pro and I have only done this one project and it wasn't even anything all that complex....

Well Paid Killer wrote:After finally seeing it, I'm very nervous about the whole thing!! :puke Is anybody out there willing to help me out on the fiberglass clean up work?? Haven't ever worked with the stuff and would hate for this to be the first trial and error project!! Have only worked with plastic materials and I don't trust myself on this one!!

fettcicle wrote:Humm....That is a great lookin can ya got there Braks.

I can think of about 100 ways in which I could respoond to that comment but I think I will just keep my big mouth shut

I ment it in the most respectable of ways! Honestly It is a very nice HELMET, I guess I should have used the word "Bucket" instead of "Can" .... Either way, It is VERY nice.

Brak's Buddy wrote:Dude, I know exactly how you feel. I was in the same boat as you! I have never even successfully pt a model together, much less something of this magnitude! It was extremely daunting at first but as you go along it gets easier and easier.

Well putting it that way I feel a ah... aHHH... OH GOD!! :puke Well not completely better but I see your point. I guess patience and bondo really become your best friends with this fiberglass stuff. At least theres a way for me to correct my flub-ups. Thanks for taking the time to calm my nerves Braks and the best of luck to you on your project!!

Wow . . . this thread I can see is going to become my saving grace!

I'm actually amazed . . and I don't want anyone to take this the wrong way but . . . I guess I just thought that everyone here was an amazing expert at all this stuff and that I was the ONLY person on the board who didn't have a clue . . . it's actually kind of nice to know there are a few people like me who are just diving in for the first time and feeling just as inadequate about it as me! hehehe

So, now I'm nervous . . . and yet, at least I feel like I'm part of a group! haha

Thanks guys!

Jer

Brak,

That looks great. At some point I hope to get a fiberglass helmet myself. Very helpful info.



Robert

Ego wrote:I guess I just thought that everyone here was an amazing expert at all this stuff and that I was the ONLY person on the board who didn't have a clue . . .

Nope. It is the other way around. There are only a handful of experts here. The rest of us just hide it well by posting a lot.

Off to a sweet start Brak's! Looking forward to more progress pics.

lol, speak for yourselves

Every time I post I get smarter, better, faster...

I am your TDH General KING!

ok, enough of that,
Phil

You've got that bucket off to a great start Brak's! I'm glad you posted...it gives me something to look forward to (and prepare me for) when I get my helmet.

That's gonna be a beauty when you're finished. And you're absolutely right, take it slow, patience will pay off big time.

hey could you take a picture with it on?

like to see the size. hehehe

I always love to watch your projects transform over the many progress shots.I can hardly wait to see the finished product painted


Steve

Nice helmet. Was gonna order order one this week but the **** hot water went out and my wife just couldn't appreciate the importance of getting this first. Would also like to see this as well on. Put your smiley T on Braks.

Definitely would like to see it on!!

Per request, here is the Fett helmet compared to my ANH stormtrooper. Please keep in mind that the Fett helmet looks a bit strange and narrow because it has no ears.

helmets off:



helmets on:


Think I put too much "padding" in my Fett helmet... it is riding a bit high..

Looks cool, Braks!

I don't know about riding too high. There always seems to be quite a bit of neck showing ESB style....I hate when the helmet sits too low, and it looks like it's sitting on some neckless shoulders, lol.

I don't see the pics......I want too

NOW I see them I didn't know you had a twin.....

That is a pretty good sized bucket!!! It'll be interesting to see a 4 helmet comparison to see the size difference.

BB.... You going ESB on that bad boy???

ROTJ is reeeeallly growing on me now for some reason, and I will be going that route this next time around.

That has a real nice shape to it

Brak's Buddy wrote:Per request, here is the Fett helmet compared to my ANH stormtrooper. Please keep in mind that the Fett helmet looks a bit strange and narrow because it has no ears.

Quick put the helmet on, youll scare the kids.

Nathan

I just have to say, I LOVE THAT DENT!

Awesome helm. Can't wait til I have the money to blow.

Now now Natty, us girls enjoy these unhelmeted pics Don't listen to him Brak's!

hey BB that helmet looks great.
and you paint the helmet ESB stile or ROTJ

(in a camp voice)
.....& fashion wise this year we see Fett going for the cool, minamalist approach.
Out goes his bulky, beaten armour & in comes a chic 2 piece black ensomble.
And that jet pack was just so last year.
We tried to use his wookie scalps as hair extension but it was just too much.

As you can see it also goes so well with the men of the Empire.

Black just never goes out of style.

Once again thankyou to our models Chip & Dale"

I don't know . . . I think it kind of goes for that zen/goth/coffe house bounty hunter kind of look . . . it works!

On a side note . . . BB, have you decided what paints you're going to be using on it yet?

Jer

i cant believe i missed this thread.

that helmet looks fantastic!!

its good to see the size comparisons as well.

i wonder what it looks like compared to my DP95 cast?

Mirax H wrote:Now now Natty, us girls enjoy these unhelmeted pics Don't listen to him Brak's!

:o


For all those asking about paint, I am currently planning to go RotJ with this helmet even though it is the ESB helmet (yes, contrary to some people's opinions, the two helmets are VERY different in shape). I do not plan to paint it myself. It has been a monumental enough task (for my fledgling skills)just to clean it up like I want it. I leave the paint to the professionals.

Natty! Actually, the black sort of reminds me of "Sprockets" from SNL.

rotj...blasphemy...


:puke


PHil

Thats great Phil!! Yeah and whats up with Brak's using an ESB helmet with ROTJ paint??? I thought he was all about accuracy? Not to mention that the ESB paint job is waaaaaaay better [img]images/smiles/icon6.gif[/img] [img]images/smiles/icon6.gif[/img] [img]images/smiles/icon6.gif[/img] Come on Brak's, don't let us down now...

lol. To each their own. However misguided it may be

just kidding around,
Phil

DITO THAT! :evil

Braks,just leave it completely as is,and go with a Pre/pre-pro suit of all white Just think of the time,and money you'll save.Not to mention that no-one to date that I'm aware of has done it.

It tis now time on zee Dented helmut ven ve daunce!!!! Braks you make me feel like a little GIRL!

I think a guy named Tim Arp has done the pre-pre-pro suit in all white. There was/is a pic on the 501st bounty hunter section.

There may be another as pictured on theforce.net's misc. fett pictures.

But it is a cool look!

Vould you like to touch my Monkey? Touch him...LOVE him!

Phil

did someone say touch my monkey?

OOT! OOT! OOT!


Man, I REALLY gotta get some sleep

WOW! This degenerated quickly! Way to go Mirax.

It was my pleasure

this thread has become tiresome.

*makes sprokets face*

Maybe we should change the board's name to "Da Dented Helmut"

Hey Brak's! How are you planning on attaching the visor? I'm going to the hardware store sometime this weekend, and I might as well pick up something for that purpose so I'll be ready when *my* helmet shows up. Are you going the adhesive route, or some kind of hardware attachment?

I REALLY want to do a hardware type of attachment but at one point during the build up I tested a hot glue attchment and I have to say that the hot glue was probably better and more stable than any hardware attachment I will ever come up with. I am just not sure at this point.

How well would epoxy work on this??

Jer

Hot glue is 'DA BOMB for lens attachments in Trooper helmets,and Fett helmets.Epoxy takes too long to dry,.....even the 5 min. set type.

Although you could "spot weld" a "T" visor in with hot glue,and then use 5 min. epoxy for the rest I suppose.The only problem is the possibility of it running before it set.

I definitely plan on doing the hot glue method with my Fett helmets as I've done on my Trooper lens'.It's as rock solid as any epoxy once you've got a good beaded amount on your visor.


Steve

Hot glue for the ears/stalk/RF too, or use epoxy for those?

I love epoxy, especially the "PowerPoxy" from WalMart. A lot of my suit it held together with it and JB Weld Quik. I've found that with both epoxy and JB Quik, there's an art to knowing how much hardener to use to prevent running.

A lot of my wife's AOTC female Tusken helmet is held together with hot glue and GOOP. I've also got some type of epoxy-like adhesive made by Loctite, and also a supply of Bondini. I've *got* the adhesives!

What type of hot glue are you using? Because any of the types I found when I was making my Tusken weren't even CLOSE to being strong enough to hold things together. Most of my Tusken head fell apart at the AOTC premier!

I'm just thinking that if hot glue couldn't hold a tusken head spike, it sure as hell isn't going to keep my visor in.

Jer

Well, it's not a Tusken *male* - it's a Tusken *female*. I've never worked on a Tusken *male* costume in particular, so I don't know the details of the assembly.

The females have helmets/masks that cover the majority of the face, with a "bib" attached to the bottom of it. The top of the helmet is covered by the long burqa-like overrobe. I constructed her helmet out of a sheet of 2mm Sintra, cut into 7 pieces, which were bent and glued or epoxied together to give the resemblance of being metal sheets welded into place. 8)

I just used standard hi-temp hot glue. I didn't even use hot melt caulk, as some people do. I do doubt that the "low-temp" hot glue would work. It may be safer to work with, but it's pretty ****** for bonding.

I've never had a problem with epoxy or hot glue adhering to Sintra.

Brak's Buddy wrote:For all those asking about paint, I am currently planning to go RotJ with this helmet even though it is the ESB helmet.

Brak's isn't the only one. I too am going to have mine painted by a pro in the RotJ color scheme.

BobaFettish wrote:Brak's isn't the only one. I too am going to have mine painted by a pro in the RotJ color scheme.

Okay, am I the only one who's going to do mine up as an ESB helmet when it comes??

Bad Braks. Bad Fettish. Go to your rooms and think about what you've done!

I'm bad too.... I'm going ROTJ on this one as well.

I just sprayed truck bed coating on mine to coat the inside. I hope to start the putty work tonight.
I have decided not to cut out the key holes out in mine, only for accuraccy sake, it is not really necessary for me any ways.

I never have needed any type of cooling in any of my helmets, it has never been a problem for me, so I'm not going to bother with it.

*WARNING*
My helmet arrived and it had some stickey residue on it in spots and I figured it was uncured resin or mold release residue so I used Acetone, what is used to clean up after using resin, to clean it off and it started to make the gelcoat sticky!!
Do not use acetone!!!
I'll try alcohol on it to clean it up, the sticky residue has to come off or the paint won't stick very well.

Hey Ego, I'm going ESB for sure!!!!

Just wash the helmet with dish washing soap and warm water..after that hit it with some comet or like I used scrubbing bubbles. The helmets are just bleeding a little bit of the gelcoat hardener. You need to lightly sand the entire helmet after that.

Lee

Isn't it funny, how all these years go by where people want a movie accurate ESB shaped helmet, and they finally get one, and they ruin it with an ESB scheme! I'm done my Pro-ESB rant now!

I just can't wait to see these helmets painted up . . any scheme . . they're going to be great. I just hope mine looks as good!

Lynn: Question for you on the truck spray there . . . never worked with it before . . what's it like? Just comes in a spray can?

Jer

Well you all KNOW I'm going ESB :evil

Steve

Ego...
The Truckbed liner coating is in a spray can like spray paint and is reeealy easy to use. You just follow the directions and spray it into the helmet.
I just masked off the helmet so that it wouldn't get all over the outside of the helmet and I sprayed three coats inside. it gives it a black hard durable coating on the inside of the helmet.

I now have my helmet's main green color painted.....

Sorry Braks if this thread got high jacked!!!
Maybe I'll start my own...

OK, I am ALMOST done!!!! I am VERY pleased with how this project is turning out, especially since it is the first kti I have ever worked on!!!

Latest Pics








You may notice that my rangefinder looks a little funny. That is because it is just hanging on the stalk. I have not glued it in place.

"impressive......most impressive." ]

Nathan

Lookin' good Braks, lookin' good indeed!

So . . when does the painting begin?

Jer

wow looks very good Brak
amazing helmet

Impressive.

Most impressive.



But your rangefinder looks funny. (Sorry, had to say it)

"Best helmet ever"

Looking good man, you're doing great....and that's your first kit? I think you've got more talent than you give yourself credit for.

oooh, can't wait 'til mine arrives...

that rocks man!!!

Cool!
Cant wait to start on mine!

"SMOKIN'"!!!!!! Does your rangefinder articulate up/down,or is it in a fixed position? What about the "T" visor situation,...how'd you fix it in place? We're all counting on you bud


Steve

looking good bud!!! I think it needs a little more paint though....

Strong work

Hey Brak's just curious... Did you already secure your visor in place or did you just put it there for reference for the pics?? Seems that it would be harder to paint it with it mounted.