Subscribe
  1. thksdad is offline thksdad
    Jun 10, 2004, 3:58 AM - cutting out the key holes??? #1

    hey, i got my helmet about 3-4 months ago. i need to cut the key holes out. i have cut the long peice out, but, how do i cut the little notch out at the top? i thought an exacto knife, but, it didn't work too well, or it might just have been me. can anyone help?
    Michael
  2. Jango's kid's Avatar
    Member Since
    Nov 2002
    Posts
    2,517
    Jun 10, 2004, 4:08 AM - Re: cutting out the key holes??? #2

    I had alot of trouble cutting out my keyholes too. finally, I got the smallest dremmel bit I could find. It is smaller than the head of a pin!!!! They are called metal etching bits, but I found that they work quite well for cutting those little suckers out. I got mine at a local Walmart. Also, if its possible, have a buddy help you by spraying the area you are cutting with an air nozzle/air compressor line as you cut. that way you can clearly see what you are doing. after that, you can further shape & straiten the holes with sanding sticks called "sanding twigs" I got some of these at hobby lobby in the modeling section. these things are tiny, but really sand well!!! worth the 99cents hope that helps
    Damian
  3. Jedi-Bob's Avatar
    Member Since
    Mar 2002
    Posts
    1,570
    Jun 10, 2004, 8:21 AM - Re: cutting out the key holes??? #3

    Jango's Kid - thats what I was going to say!
    After the dremel I used ordinary emery boards my wife had lying around. Worked like a charm.
  4. E2K13's Avatar
    Member Since
    Apr 2004
    Posts
    1,501
    Jun 10, 2004, 10:07 AM - Re: cutting out the key holes??? #4

    I am going to have to tackle this project fairly soon. Marrow_Sun suggested using a dremmel with a small bit to make several small holes and then widen the holes and shapen the area using hobby files. The hobby files are similar to an emery board but have different shapes for squaring out the corners. I picked up a set of Hobby Files from a local Hobby Shop and they were like $17.00 for an assortment of 12 different shapes.
  5. GuinnessNM's Avatar
    Member Since
    Jun 2003
    Posts
    213
    Jun 10, 2004, 10:33 AM - Re: cutting out the key holes??? #5

    I did the same thing as E2K13 and it works like a charm. The filing takes a bit of time, but the final product will come out much nicer.
    These are the types of files you need..
    http://www.hobbylinc.com/htm/exl/exl55608.htm

    Erik
  6. thksdad is offline thksdad
    Jun 10, 2004, 11:24 AM - Re: cutting out the key holes??? #6

    thanks. okay, so, i just cut the key holes out....at least, i tried to. well, some of the top notches are bigger than others. can i just start all over...and by that i mean, could i use some Bondo to fill all the holes in, and recut them out? what would you guys do?
    Michael
  7. GuinnessNM's Avatar
    Member Since
    Jun 2003
    Posts
    213
    Jun 10, 2004, 11:36 AM - Re: cutting out the key holes??? #7

    I would think that you could use a little bondo to even them out a bit. Have not had to do that myself so I could be wrong, should work though.

    Erik
  8. thksdad is offline thksdad
    Jun 10, 2004, 1:35 PM - Re: cutting out the key holes??? #8

    thanks, i'll try it, and let you guys know how it works.
    ~Michael

Similar Threads

  1. Holes on the rocket /Jet Pack
    By Madrid Boba in forum Boba Fett Costume
    Replies: 11
    Last Post: Nov 16, 2007, 12:26 PM
  2. Cutting Holes in Backplate for Jet Pack Straps:
    By Dha Syntir in forum Boba Fett Costume
    Replies: 4
    Last Post: Jan 21, 2007, 1:41 PM
  3. cutting holes for lights in alluminum ?
    By BH2372 in forum Boba Fett Costume
    Replies: 3
    Last Post: Aug 8, 2004, 12:52 PM
  4. Should I cut the Key holes out????
    By BFett88 in forum Boba Fett Helmet
    Replies: 5
    Last Post: Jul 18, 2004, 9:53 AM
  5. Need measurements for JP holes in the backplate
    By OPPI in forum Boba Fett Costume
    Replies: 1
    Last Post: Jun 7, 2004, 1:11 AM