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  1. Hand-Schaub's Avatar
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    Sep 25, 2002, 3:23 AM - CAST ALUMINUM FETT (phase 2) - w/ comparisons #1

    Here it is - my scratch sculpted Fett helmet is cast in aluminum!

    After my first try with the DP delux casting I decided to improve my techniques. I'm quite proud of this especially because I actually sculpted the master helmet. I was able to make the walls very thin so the helmet is very light and wearable! It weighed in at 5lbs but it doesn't seem like it. I guess that would be because the helmet is quite large but the metal is evenly distributed making it more comfortable on the head than one might think.

    Pics show progress of the clean up. The surface is really smooth and straight - although it looks like it has wrinkles and dirt. Next step is to "flap" it and wire wheel it for that oh-so-smooth surface.

    So... here are the pics - ask me what you want to know...










  2. Member Since
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    Sep 25, 2002, 3:52 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #2

    Dude you rock. That is so cool. how can you cast aluminum stuff in your garage ? Do you have a mini blast furnace ?
    ST
  3. Well Paid Killer's Avatar
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    Sep 25, 2002, 4:56 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #3

    Yes very nice, I'll take 2 of them please, thank you!!!!!!!
  4. Admin Staff Star Wars Chick's Avatar
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    Sep 25, 2002, 10:23 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #4

    That is awesome work!
  5. gwizah_fett
    Guest
    Sep 25, 2002, 11:05 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #5

    wow! Pretty mindboggling
    5 pound helmet made of aluminum...I wonder how much protection that pot would actually offer?

    Theres goes another few hundred bucks hehehe.. PM me!
  6. Ego
    Guest
    Sep 25, 2002, 11:45 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #6

    Man, people making metal helmets, metal armor . . . . just need someone to start making small flamethrowers and you could actually BE a real Boba Fett bounty hunter!

    Great work on the helmet. Looks incredible!

    Jer
  7. BOBA PHAT's Avatar
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    Sep 25, 2002, 3:10 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #7

    That looks fantastic! It goes to show that we can do anything if we put forth the effort. Good job, man!
  8. malcfett's Avatar
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    Sep 25, 2002, 3:21 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #8

    It makes me sick how talented some of you
    people are! uke

    Just kidding. That helmet came out superb!!!
  9. Member Since
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    269
    Sep 25, 2002, 4:44 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #9

    Looks great stay indoors when it storms.

    Oh and I want one!
  10. Vec Toryn
    Guest
    Sep 25, 2002, 4:50 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #10

    OMFG! That's awsome!
  11. Boba Phett's Avatar
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    Sep 25, 2002, 8:27 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #11

    Nice bucket!!!

    Somebody say working flamethrower?
  12. Fett Gal
    Guest
    Sep 25, 2002, 9:45 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #12

    WOW!! That's amazing. That I could be so talented.
  13. Mandalorian70
    Guest
    Sep 25, 2002, 11:34 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #13

    Dang !!!!!!

    That is just TOO Awesome !!!

    My compliments on your work Friend !!!

    Take Care

    John
  14. Hand-Schaub's Avatar
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    Sep 27, 2002, 12:36 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #14

    Thank you for all the wonderful compliments! :o

    I'll be cleaning it up more soon and sharing new pictures as well. In regards to the garage blast furnace...no. I actually work at a commercial art foundry where we specialize in individual castings and what not (but yeah - as if I would cast just "one"). I just completed a new thread on the process of casting in aluminum. Here it is:

    http://forum.thedentedhelmet.com/vie...c=2370&forum=2

    Oh - I want one of those flame things!
  15. Hand-Schaub's Avatar
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    Oct 5, 2002, 2:24 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #15

    for comparison...also it shows the new aluminum helmet cleaned up some more. It can still be polished with a fine wire brush. Once the rangefinder cover is tapped then the cover will be secure and the rangefinder positional



    notice the thickness of the metal - remember, this is cast!

  16. MaxPlague's Avatar
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    Oct 5, 2002, 2:57 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #16

    Damn that's a sweet helmet! I think I'll call you Master Caster.
  17. Hand-Schaub's Avatar
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    Oct 5, 2002, 3:50 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #17

    You said 'Master' huh-huh! (Insert image of Beavis and Butt-head here)

    I like that!
  18. Member Since
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    Oct 5, 2002, 12:07 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #18

    Strong Work!!!
  19. CaptainSolo
    Guest
    Oct 5, 2002, 1:27 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #19

    That looks great, guess I'll be heading to the cargo hold.




    Robert


  20. Hand-Schaub's Avatar
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    Oct 7, 2002, 1:01 AM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #20

    CaptainSolo wrote:That looks great, guess I'll be heading to the cargo hold.
    You can bet us metal headed Fetts mean business!
  21. Hand-Schaub's Avatar
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    Oct 11, 2002, 10:20 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #21

    Here are some progress pics. The rangefinder stands on its own. A screw is holding the ear cover in place. Also you can see the thickness of the metal in the 'inside' shot. Because Boba is painted I decided not to 'polish' the helmet up and leave it a bit textures so the paint sticks better.










  22. Admin Staff Star Wars Chick's Avatar
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    Oct 11, 2002, 10:39 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #22

    Really awesome work there!
  23. fettcicle's Avatar
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    Oct 12, 2002, 2:09 PM - Re: CAST ALUMINUM FETT (phase 2) - progress pics #23

    That looks like a GREAT helmet, I wish I had one ..... JUST LIKE THE ONE PICTURED
  24. Hand-Schaub's Avatar
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    Oct 17, 2002, 2:32 AM - Re: CAST ALUMINUM FETT (phase 2) - w/ comparisons #24

    Thought I would show a few comparison shots. From left to right:
    DP97, my aluminum helmet (not cleaned up) and DP95/6 FG cast

    Thanks to Chrima for taking these shots and the use of his wonderfully painted helmets.





  25. I helped at SDCC '08 journeymanprotector's Avatar
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    Oct 17, 2002, 3:02 AM - Re: CAST ALUMINUM FETT (phase 2) - w/ comparisons #25

    I love the flare on your helmet, looks great! I can't wait to see it done up

    Phil

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