Cardboard Fiberglass Composite

**Warlord** · 02-10-2007, 07:31 AM

Ok, I've been led to this site via Honus' instructable on how to make a fett helmet out of cardboard. I searched the site and read up on a lot of scratchbuild techniques before starting my build.

Thanks to Honus and others for the inspiration and to Alan (WOF) for the templates.

For the cardboard I'm using mat backer board - It's some type of cardboard/paperboard used in mounting pictures in frames. It curves well without creasing and a full sheet was $0.99 from the local craft supply. That's for enough material to complete this project

!

I had a partially used Bondo fiberglass repair kit which was used to fix a split in my bumper. It would probably have gone to waste in my garage but now it's going to help me make a durable, affordable Fett Bucket!

Here's my progress so far:

Roughed together:

Back insert remover to ease the interior fiberglassing, you can see the sheen from the Mod P:

Here you can see the interior covered with the woven fiberglass and resin:

The excess fiberglass mat has been trimmed off on the right using a dremel sanding wheel:

Fully fiberglassed dome the exterior cardboard is now only for detail, not strengh:

**Spideyfett** · 02-10-2007, 08:13 AM

Wow

those are some nice clean edges you got on that thing.....Lookin good..

**KaanE** · 02-10-2007, 10:55 AM

Good work and very clean

Now the rear part no?

**DL44 Blaster** · 02-10-2007, 11:57 AM

WOW!!!! VERY nice build skills! The lines are super crisp and the matting looks extra neat. Going to be a nice bucket. Check out RS's ears to be sure and get the best for it

Steve

**t_bone9600** · 02-10-2007, 01:24 PM

Very nice so far! I look forward to seeing it finished. Keep up the good work!

**sithlord23** · 02-10-2007, 02:13 PM

Very nice work man! Keep us posted on your progress!

**Warlord** · 02-10-2007, 05:54 PM

Thanks everyone.

Don't worry, I'll keep up with the updates. I hate seeing good scratchbuild threads just go dead with no explaination.

So far I've sanded down the ridges on the dome where the cardboard is joined to remove the 'faceted' look. In some places i've gone all the way down to the fiberglass to get the smoothness right. This should help when I apply the bondo to get a nice rounded dome; I won't have to worry about the ridges showing through when I sand it down or paint it.

The rear will go back on and I'll fiberglass that into place and use a temporary wire form to add a little 'flare' before I start the bondoing process.

I'll probably have more pics up on Monday or Tuesday.

**never_ending_fett** · 02-10-2007, 07:50 PM

great looking start! You got some skills.

**CombatBaby** · 02-11-2007, 02:24 PM

whoa, that is a very nice looking cardboard helmet.

are you planning on making the ears too? or will those be resin?

-=QuinN!

**Warlord** · 02-11-2007, 03:03 PM

I've taken a rasp (actually a small handheld grater) and took down the high points on the dome, as mentioned before. It's a little fuzzy but a lot smoother. I noticed in the pics that the fuzziness makes the ridges appear to be raised but that's just an optical illusion.

As far as ears go, I'll probably continue with the cardboard. I really want to see what can be done with this method.

**Warlord** · 02-11-2007, 06:13 PM

First stage bondo dome smoothing:

**Warlord** · 02-13-2007, 06:34 AM

Ok, got the back on so I needed the keyholes. Up to now I've been printing out WOF's templates, cutting them out and transferring them to cardboard by pen. This was to sloppy a method for the fine details of the keyholes so I just measured them with a good ruler and laid out the dimensions directly on the cardboard.

The results:

I alsto picked up some needle files do I can keep the details crisp.

I still have to do some more dome smoothing but this upper ear part would only be harder to do later if I didn't rough in the shape.

BTW is there a mod who can change the title to say "Scratchbuild: Carbon Fiberglass composite"?

**KaanE** · 02-13-2007, 08:28 AM

Can you see in this photo that the keyhole is sloping? Really good work on the helmet.

**Warlord** · 02-13-2007, 09:46 AM

Originally Posted by KaanE

Can you see in this photo that the keyhole is sloping? Really good work on the helmet.

Thanks. Yes, I'm aware of the slope. The curve will be set by the pieces used to inset the keyhole -which I haven't cut yet. I'll probably get as far as mounting the keyholes, fiberglassing the back, and priming the dome today.

**Warlord** · 02-13-2007, 11:36 AM

Interestingly enought I couldn't find the keyhole 'slope' in WOF's templates. I don't know if I just overlooked it or what. I even rechecked the .pdf's. Oh well I just have to do it myself, I used KaanE's pics for a quick and dirty reference BTW

And just like that it's done. the Mod Podge isn't even dry yet:

**KaanE** · 02-13-2007, 11:57 AM

If you need more photos of the helmet of Boba Fett, go to this link:

http://www.thedentedhelmet.com/misc/tdh_ref/

Is from AoSW, MoM and HD Screencaps (NEW).

**RedFilter** · 02-13-2007, 08:41 PM

So, to start this out with cardboard, what did you use to hold the cardboard together? Tape? Elmers? That sounds a lot more cost effective when I will be starting out.

**GCNgamer128** · 02-13-2007, 09:06 PM

This helmet is looking fantastic!!

**Warlord** · 02-13-2007, 10:35 PM

I used low temp hot glue to tack everything together. I butt the pieces together and apply a small amout of glue. Then I go back over it with the tip in a zigzag motion to smooth it out flat.

It's nice because it's reworkable. I originally had the keyhole in the frame upside down but was able to remelt the glue mount it correctly.

**Warlord** · 02-19-2007, 07:11 AM

Oh yeah, thanks for the comment and thanks for the link. You forgot to give me the username and password but I found it

I'm a little further on the helmet but I've also been working on the wife's lightsaber this week so that's slowed me down.

**deadbolt** · 02-19-2007, 08:31 AM

Awesome work man!! The keyslots look flippin' sweet!!!

**Warlord** · 03-05-2007, 02:12 PM

Just got back to working on it. I'm working on probably the hardest part of the cardboard helmet dome smoothing. Sure I can just continue from where I am but I think getting a nice smooth dome will help keep it looking like I made it myself.

More dome smoothing:

**Rat_Fett** · 03-05-2007, 02:53 PM

Uh....what helmet?

**wizardofflight** · 03-05-2007, 03:42 PM

Great work!! That is really looking sweet. By the way you didn't miss anything it was me that forgat to include those parts. They will be added at the next revision though.

Keep us posted, can't wait to see it finished.

Alan

Originally Posted by Warlord

Interestingly enought I couldn't find the keyhole 'slope' in WOF's templates. I don't know if I just overlooked it or what. I even rechecked the .pdf's. Oh well I just have to do it myself, I used KaanE's pics for a quick and dirty reference BTW

**Man of War Studios** · 03-05-2007, 04:19 PM

Great Job, Way to be inventive

**superjedi** · 03-05-2007, 05:54 PM

Hmm. . . in that last pic you posted I'm assuming there's supposed to be a helmet there somewhere.
Must be some kind of optical illusion.

**Warlord** · 03-05-2007, 11:34 PM

Haha! Yes hidden in the above photo is my helmet undergoing smoothing. Here's a few updates of the smoothing progress for today. Just put a fresh coat of sandable primer on, waiting to dry. Try not to get distracted by my rotating desktop pics; the helmet really is in there:

**Predatormv** · 03-06-2007, 02:30 AM

Well I see a nice smooth round thing but I think my eyes are playing tricks on me since I see two of them...

**AFettFullofDollars** · 03-06-2007, 04:50 AM

Not to be a wet blanket, because I love a good 'smooth dome' tutorial as much as the next guy, but those screensavers on your computer probably violate the boards 'Family Friendly' CoC, and may end up getting your helmet pics pulled.

**mrgr8ness** · 03-06-2007, 06:18 AM

Yes you should just send all future "dome" progress pics to my email address with a CC to the Sniffers email address

This will help keep the site friendly

**Southern hunter** · 03-06-2007, 07:07 AM

Heck, e-mail me the pix on your screen saver!

**Warlord** · 03-06-2007, 08:04 AM

I'll turn off the monitor before I take pictures from now on, LOL. If you guys want a link to the wallpaper sites I used I can do that as well. I know how hard it can be to get a nice 1680x1050 wallpaper still.

**stormtrooperguy** · 03-06-2007, 02:07 PM

Originally Posted by Warlord

I'll turn off the monitor before I take pictures from now on, LOL. If you guys want a link to the wallpaper sites I used I can do that as well. I know how hard it can be to get a nice 1680x1050 wallpaper still.

yeah... i pretty much make all of my own desktop images just for that reason (20" imac). my screen is usually either something star wars or something naughty

great looking helmet too!

**Ekelki** · 03-06-2007, 07:44 PM

Wheres the screen saver link?

**Warlord** · 03-07-2007, 09:58 PM

Ok, I decided to add about a 1/2" to the top of the helmet. I had originally removed it from the "flatpack dome" templates but my eyes line up too low in the visor opening even after grinding down the cardboard cross supports. Here's the work:

Cut:

Temporarily held in position:

I've already attached it with fiberglass now I just have to Bondo and fill the gap. More pics soon.

**zombierepellent** · 03-07-2007, 10:07 PM

That is unbelievably smooth for being done with cardboard.

**Warlord** · 03-08-2007, 04:08 PM

Ok, fiberglassed in placed and filled with Bondo.

I've already ground down the bondo and am currently waiting for the putty to harden so I can finish smoothing the dome. Next are the ears.

**TeeVee8** · 03-15-2007, 06:26 PM

I hope the cardboard doesn't make the helmet overly flammable

Tidy work so far.

**CGClone** · 03-15-2007, 08:00 PM

Impressed, inspired and overall, nice nice, excellent work! :thumbup

Cardboard Fiberglass Composite

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