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  1. formerly Sgt. Skirata Huntman's Avatar
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    Sep 3, 2008, 7:38 PM - Broken boba helmet tutorial #1

    So a guy here is getting married and needs a couple of helmets done. unique situation. Well his delima is h has already bought two kits and tried to get these custom mando helmets done for his wedding and it sems he is having a problem. SO I promised to help him out Here is what I got in the mail yesterday.

    I noticed a couple of fairly common mistakes with this pair of Bradley fett kits. the brow rim was cut from the inside of face and back see where my finger is pointing and the front and the back were trimmed too short where they meet.
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  2. formerly Sgt. Skirata Huntman's Avatar
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    Sep 3, 2008, 7:49 PM - Re: Broken boba helmet tutorial #2

    As you can see the dome was crooked as well. See this is Jazz inspecting it. I was very... intimidated by the scope of the Project even though my own 501st bucket is a Bradleyfett. I knew the mistakes that are on it , Only I will notice but still I was really hoping this would turn out well. So I stuck one foot in front of the other and cut out the turn signals first.


    Then I used some of the part of the trim from the helmet and some PVC glue to back the signals
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  3. formerly Sgt. Skirata Huntman's Avatar
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    Sep 3, 2008, 8:01 PM - Re: Broken boba helmet tutorial #3

    I used waky tack to hold the dome in place whilst I applied teh PVC glue to the edge then fit the face mask to the front. Remember to center it on the blinkers ( arrows on the brow). The glue will take 45 sec to a min to dry. watch for drips as this stuff melts the plastic together!
    Do not be afraid if you have to reapply for the edges of the mask to moor them to the dome.

    repeat with the back. watch to make sure the brow sticks out a little farther than the dome ( if possible). Remember this is a how to fix thread. There may be spots where ya' just cut it too close and ya' gotta' make do I guess. I had one spot on helmet # 2 above the right brow where this was the case.
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  4. formerly Sgt. Skirata Huntman's Avatar
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    Sep 3, 2008, 8:05 PM - Re: Broken boba helmet tutorial #4

    As you can see there will still be gaps in the dome and if the mask and rear are cut too short in the side. one thing at a time. I went and got a NO PARKING sign and PVC glued cut peices to the inside of the helmets ears. This will stabilize the helmet masks to be more solid. Do not use the painted sign as the side to adhere to the helmet!!
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  5. formerly Sgt. Skirata Huntman's Avatar
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    Sep 3, 2008, 8:09 PM - Re: Broken boba helmet tutorial #5

    Here is a pic of the glues sign/ears next I bondoed the rim of the dome ( from the inside) some bondo il ooze out. Finger smoothit to seal most of thye crackes and fill all holes at this time.
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  6. formerly Sgt. Skirata Huntman's Avatar
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    Sep 3, 2008, 8:14 PM - Re: Broken boba helmet tutorial #6

    Last part I will get done today. After I Bondoed the helmet ( not pictured just too messy to handle the camera right then). I took the helmets outside. The guysaid he would reimbuse me for materials so here is my secret 10.00 ingredient.

    I used a can of truck bedlinder to firm up the helmet from the inside as well as add a nice finish to the inside. I used 3 coats. the helmet becomes a bit sturdier and heavier.
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  7. ioelus's Avatar
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    Sep 3, 2008, 8:32 PM - Re: Broken boba helmet tutorial #7

    I used the bed liner on the inside of my Bradleyfett, too. Didn't add as much structure as I hoped, but it helped.

    Keep those pics coming.
  8. formerly Sgt. Skirata Huntman's Avatar
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    Sep 3, 2008, 9:11 PM - Re: Broken boba helmet tutorial #8

    I had no illusions about it being the quarter inch stuff that the professionals use. But it was still a huge improvement and it looks nicer than the white marked up plastic. I ran into a problem with the fiberglass falling out and flaking from my own helmet so i knew that wouldn't do.
    The visors should add even more strength.
    I will add more pics as the work gets done.
  9. formerly old_jedi_mind_trick Bobby Fett UK's Avatar
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    Sep 4, 2008, 6:06 AM - Re: Broken boba helmet tutorial #9

    I have put two of these together.....but I don't understand what the thread is about?

    Also, I find it really solid without the need for the inner lining?
  10. formerly Sgt. Skirata Huntman's Avatar
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    Sep 4, 2008, 10:38 AM - Re: Broken boba helmet tutorial #10

    The thread is about common mistakes in assembly and a step by step how I did it. I may well be strong enough if you do not have the Gapes where a sign or plastic is needed for a patch.
    My helmet is strong enough too BUT I feel a lot better when I strengthen all the helmets I do. I just like them to survive the occasional accident as much as possible.
    I even strengthen the resin helmets I do but I use fiberglass there.
  11. formerly old_jedi_mind_trick Bobby Fett UK's Avatar
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    Sep 4, 2008, 10:47 AM - Re: Broken boba helmet tutorial #11

    Ok. I like the look that black stuff gives the inside, and you can add strength if you need it, thats cool. What was trimmed too much, I can't see to well, maybe the size of the photo. Is it the brim (top of the mandibles) or the sides?

    Just trying to understand bro, Like I said, I have built two up and am a little lost, for someone who has not seen one.......

    Rob.
  12. Stormrider's Avatar
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    Sep 4, 2008, 10:56 AM - Re: Broken boba helmet tutorial #12

    Awesome job brother. Nice tips.

    I think what was trimmed too short was they trimmed the helmets on the sides. They are supposed to overlap, but I think he took them off to the point where they no longer overlapped, but butted up? If im understanding you right? Meaning that you had nothing to adhere/brace too?

    I like the bedliner idea. Question, and a silly one. Whats in bedliner? seems it would make a nice dippable gap filling liquid. Id like to try it on some of my parts to reduce detail in sharp edges.

    I just wonder if its got sulfer or latex in it.

    Awesome thread. Thanks
    Mason Stormrider
  13. formerly old_jedi_mind_trick Bobby Fett UK's Avatar
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    Sep 4, 2008, 11:21 AM - Re: Broken boba helmet tutorial #13

    OK, I trimmed mine short but Mark supplied some extra plastic to reinforce (or join) the ears on the inside, well I used it for that and it worked out great. I used bondo to finish the outside which made it pretty solid and filled the gaps. Funnily enough I put your ears on it Stormrider, it is now half painted and they really look great.

    Hey great work cutting out the turn arrows Sarge.....mine were bad and took some work to get them looking how I wanted them to.

    I sanded the brow as square as I could to give it a more fiber glass look, with the benefit of being very light.
  14. formerly Sgt. Skirata Huntman's Avatar
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    Sep 4, 2008, 11:30 PM - Re: Broken boba helmet tutorial #14

    Thanks. I was intimidated so i started small. That's really how every artistic endeavor starts with me.
    Hey can ya give us a pic of where ya sanded the brow square?
    Mark is a great guy. You are so right the helmets are deceptively light but sturdy.
    Stormrider you are correct about the cutoff. I have heard of more than a few guys doing this though so I figured I would post my second tutorial.

    the stuff is in a spray can but I did see some dippable stuff which seems he same in the store with the big orange sign Home----t. I thyink it's latex but will have to get back to ya on it.

    The great part about this project is the cost of the parts can be streatched over two helmets with little to no waste and saving money. Plus it saves the owner from having to buy the dremel, bits x-acto and sander.Gosh know I have enough paints, wood and muslin left over from my normal painting.What a waste that box of stuff is..
    Last edited by Huntman; Sep 4, 2008 at 11:37 PM.
  15. brokenboba's Avatar
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    Sep 5, 2008, 12:45 PM - Re: Broken boba helmet tutorial #15

    HEY HEY, It looks awsome! obviously better then what I could acomplish, lol. Just a note I only trimmed the dome. The face and back I never touched. I will reemburse all your cost plus a touch extra!! As soon as my special material arrives ill snap some pics before I start my build to show you what sceme is!!
  16. formerly old_jedi_mind_trick Bobby Fett UK's Avatar
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    Sep 5, 2008, 4:53 PM - Re: Broken boba helmet tutorial #16

    Ahhhh...Broken Boba, I see.

    I will post up some shots tomorrow...in fact...here is a quick one I have.


    Will post up something on the squared off brow asap...bed time here! I simply sanded the top, bottom and face....I figured if I went through I would use some filler, but I got bored sanding before that happened and it looked good enough.

    This is for a custom, with a Pre Pro Supertrooper twist.
  17. formerly Sgt. Skirata Huntman's Avatar
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    Sep 6, 2008, 12:26 PM - Re: Broken boba helmet tutorial #17

    wow that's awesone I can't wiat to see the dent too. How did you do that?
  18. formerly old_jedi_mind_trick Bobby Fett UK's Avatar
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    Sep 6, 2008, 1:11 PM - Re: Broken boba helmet tutorial #18

    Here are some photos, this is still a WIP. The Dent was done by heating the area up with a heat gun and pushing it in. I went for a FP style double dent. Can't really capture the sanded square brow, but hopefully you cas see from looking front on?



  19. brokenboba's Avatar
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    Sep 6, 2008, 8:06 PM - Re: Broken boba helmet tutorial #19

    Sgt, I have a question if you can pull it off. Can you put a close call from a light saber going down the face from the dome down over the T? Ill see if I can draw something up or get the idea across to you. The over all helmet is going to be black w some red trim, maybe the V area of the T visor will be red, just an idea. Since your doing the work, that is so far very awsome, :thumbup ill give you the creative freedom to play with it. I dont mind battle damage one bit ether.
  20. formerly Sgt. Skirata Huntman's Avatar
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    Sep 6, 2008, 8:13 PM - Re: Broken boba helmet tutorial #20

    I will wait til i see your sketch I want to see where you want the close call. In the center right or left? Also i am looking forward to your color scheme. Black and red very nice
  21. brokenboba's Avatar
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    Sep 6, 2008, 8:29 PM - Re: Broken boba helmet tutorial #21

    Ill see what I can draw up, I want it down the right side were the eye would be. here is something I would eventually like my Mando to look like. Ill try and get the pic to you tonight my time.
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  22. brokenboba's Avatar
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    Sep 6, 2008, 8:46 PM - Re: Broken boba helmet tutorial #22

    Here is my idea#1 and the front of my Kama , you can see the color scheme
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  23. brokenboba's Avatar
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    Sep 6, 2008, 8:48 PM - Re: Broken boba helmet tutorial #23

    The astrik is were I will be installing 2 greebles that are turned aluminim.
  24. brokenboba's Avatar
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    Sep 6, 2008, 8:52 PM - Re: Broken boba helmet tutorial #24

    My other idea is the bantha skull over the helmet just off center and up to the right in red with a black helmet what do you think? This one has more attitude. With blast marks & close call too.
  25. formerly Sgt. Skirata Huntman's Avatar
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    Sep 11, 2008, 12:41 AM - Re: Broken boba helmet tutorial #25

    well here's my progress. I did most of this last weekend. I cut out the key slots. cut and installed the foam with velcro ( like a bike helmet) that way It can be adjusted. Oh and I cut the visor out and dis some sanding.
    I can definately do the cut over the right eye.
    At this point I made the cuts on the key slots of helmet # 2 but chose to focus on the better of the two helmets to get at least one of these finished asap. Still waiting on the back ordered visor for helmet # 2
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