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CAST ALUMINUM FETT (phase 2) - w/ comparisons

  1. #1

    CAST ALUMINUM FETT (phase 2) - w/ comparisons

    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. #2

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    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. #3

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    Yes very nice, I'll take 2 of them please, thank you!!!!!!!

  4. #4
    Admin Staff Star Wars Chick's Avatar
    Member Since
    Mar 2002
    From
    Kingman, Arizona, United States, 107964532558835, Kingman, Arizona
    Posts
    5,575

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    That is awesome work!

  5. #5
    gwizah_fett
    Guest

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    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. #6
    Ego
    Guest

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    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. #7

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    That looks fantastic! It goes to show that we can do anything if we put forth the effort. Good job, man!

  8. #8

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

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

    Just kidding. That helmet came out superb!!!

  9. #9

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    Looks great stay indoors when it storms.

    Oh and I want one!

  10. #10
    Vec Toryn
    Guest

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    OMFG! That's awsome!

  11. #11
    Boba Phett's Avatar
    Member Since
    Mar 2002
    From
    NW of Chi-town
    Posts
    254

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    Nice bucket!!!

    Somebody say working flamethrower?

  12. #12
    Fett Gal
    Guest

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    WOW!! That's amazing. That I could be so talented.

  13. #13
    Mandalorian70
    Guest

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    Dang !!!!!!

    That is just TOO Awesome !!!

    My compliments on your work Friend !!!

    Take Care

    John

  14. #14

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    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. #15

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    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. #16

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    Damn that's a sweet helmet! I think I'll call you Master Caster.

  17. #17

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

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

    I like that!

  18. #18

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    Strong Work!!!

  19. #19
    CaptainSolo
    Guest

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

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




    Robert



  20. #20

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    CaptainSolo wrote:That looks great, guess I'll be heading to the cargo hold.
    You can bet us metal headed Fetts mean business!

  21. #21

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    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. #22
    Admin Staff Star Wars Chick's Avatar
    Member Since
    Mar 2002
    From
    Kingman, Arizona, United States, 107964532558835, Kingman, Arizona
    Posts
    5,575

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    Really awesome work there!

  23. #23
    fettcicle's Avatar
    Member Since
    Mar 2002
    From
    Chicago
    Posts
    1,263

    Re: CAST ALUMINUM FETT (phase 2) - progress pics

    That looks like a GREAT helmet, I wish I had one ..... JUST LIKE THE ONE PICTURED

  24. #24

    Re: CAST ALUMINUM FETT (phase 2) - w/ comparisons

    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. #25

    Re: CAST ALUMINUM FETT (phase 2) - w/ comparisons

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

    Phil

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