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  1. Member Since
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    Sep 7, 2010, 9:46 PM - Davehal9000's styrene helmets using WOF templates #1

    While my kids were here for the summer I got a wild hair and decided to try my hand at making my sons posterboard Fett helmets. While searching for a formula for making the dome I found this site, and my life's been in shambles ever since!

    When we went to the MoM show up in Huntsville my oldest wanted one of the Jango costumes that had at the gift shop. I got it for him but he was disappointed in it to say the least. I set out to build him a decent helmet and am now neck deep in two full costumes!

    I took a guess at what size helmet I'd need and went to work on a Jango helmet. My intent was to use posterboard and impregnate it with resin. I ended up using glass sheet as well. In the end I added styrene for the outer layer and it worked out well. However, I won't go the resin impregnated route again after seeing how easily knee armor and cod pieces done the same way came apart.

    When I got to the cheeks I got worried the helmet may be too small. My son's several states away, so no way to try it on. About that time my youngest announced he wanted to go as Boba, so the Jango helmet became a Boba.

    Click image for larger version. 

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    Again, not being sure what size to make the helmet I had to guess. Hearing some adults find the WOF helmet templates a bit small I figured it best and easiest, due to computer/printer issues, to use them full sized. Plus it'd give him room to grow into it.

    The second helmet I made strictly out of sheet styrene and fiberglass. The templates used to form the dome and bucket were cardboard, so there's a strip here and there deep under the fiberglass.

    Click image for larger version. 

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    Anyway, this is my progress so far. By an odd twist of events I'll get to see the boys briefly this week, giving me a chance to see if the helmets and single gauntlet I've built so far will fit.

    Click image for larger version. 

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  2. Evilhemmes's Avatar
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    Sep 7, 2010, 10:27 PM - Re: Davehal9000's styrene helmets using WOF templates #2

    Mate they look awesome, wish i ihad the time to try this, my 2 minihumans are under 2 and half, i could never get the time, they run me off my feet. Keen to keep following this intently
    great work.
  3. Member Since
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    Sep 25, 2010, 12:56 AM - Re: Davehal9000's styrene helmets using WOF templates #3

    Some progress, just before painting. I took some liberties on the keyhole area to make it more durable for my son. This will be a Boba helmet and I'm chugging right along on Jango









  4. Ghostwalker's Avatar
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    Sep 25, 2010, 11:28 AM - Re: Davehal9000's styrene helmets using WOF templates #4

    Vod these are putting me to shame.
    Excellent builds ... and that's all I have to say surprisingly.
  5. Member Since
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    Sep 26, 2010, 1:48 AM - Re: Davehal9000's styrene helmets using WOF templates #5

    Thanks!

    Got the first two layers of paint on tonight. I'm finding myself running out of time and am having to work faster than I'd like to. I didn't polish this one up before painting. The major sanding marks were taken care of but I missed slight flaws here and there. I'm sure no worse than the flaws on the "real" helmets, but it bugs me all the same.

    I'm using latex mold building material as a mask and it seems to be working fine. Hopefully I can get the latex to rub off after the painting's done. If not, some ultra-fine steel wool should help. I didn't go to the extreme of using the stencils posted on the forum but am using them as a reference. It won't be exact, but it'll be close enough for a kid's Halloween costume. I'll try to post some pics after my next masking session.
  6. Evilhemmes's Avatar
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    Sep 27, 2010, 7:49 PM - Re: Davehal9000's styrene helmets using WOF templates #6

    looking real good Davehal9000 real good!
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    Sep 29, 2010, 10:13 PM - Re: Davehal9000's styrene helmets using WOF templates #7

    Not shooting for a super accurate paintjob but still need to do some touch-ups. Still need to get the ears painted and obviously add the visor

  8. TerranCmdr's Avatar
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    Sep 30, 2010, 3:31 AM - Re: Davehal9000's styrene helmets using WOF templates #8

    Really fantastic! The shape and details came out perfectly in my opinion. Any chance you could share a little bit about the styrene process?
  9. Member Since
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    Sep 30, 2010, 6:19 PM - Re: Davehal9000's styrene helmets using WOF templates #9

    It's pretty simple. I us sheet styrene from US Plastics. I think with shipping and all it was like $12 for a sheet 4 x 8 feet. I use the WOF templates but cut the dome forming templates out of cardboard simply due to it's thickness. The rest is styrene. I use model cement on the dome to glue the "fingers" together. Once I'm done with the dome, have it sanded, properly formed and smooth, I glue the interior layer of the helmet to the bottom of the dome using cyano cement. From there I add the outer layer, again using cyano. I cut out the dome base, then fiberglass it all to allow it to survive my boy's rough handling. Instead of fiberglass cloth I'm now using the strips used for sheet rock Works for me anyway.
  10. TerranCmdr's Avatar
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    Oct 1, 2010, 12:42 AM - Re: Davehal9000's styrene helmets using WOF templates #10

    Wow, thanks for the in-depth explanation! What is styrene like exactly? Is it very bendable? I'm just trying to decide to go with styrene or stick with full cardboard.
  11. Member Since
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    Oct 1, 2010, 12:52 AM - Re: Davehal9000's styrene helmets using WOF templates #11

    I'm using .30" sheet and it's very flexible. No issues having to force it to bend. Cuts can be made with scissors or when precise cuts are needed, a couple of passes with an X-acto. It's not quite as thin as posterboard but it's just as easy to work and a lot more durable
  12. Ghostwalker's Avatar
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    Oct 1, 2010, 2:53 AM - Re: Davehal9000's styrene helmets using WOF templates #12

    so same cost to cardboard and no worries about mold/mildew.
    I think you just sold me Styrene, Vod.
    Got a feeling my Bucket will be to big to pass approval over at the Mercs, so looking at building another set of Buckets before Christmas.
    (wife's co-worker spotted my WIPs in the living room and asked for one for his son)
  13. Member Since
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    Oct 1, 2010, 9:02 AM - Re: Davehal9000's styrene helmets using WOF templates #13

    The styrene costs a little more but no worries about it ripping apart, no waiting for it to dry, and no issues with glue or paint as people run into with other plastics.
  14. Ghostwalker's Avatar
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    Oct 1, 2010, 9:50 PM - Re: Davehal9000's styrene helmets using WOF templates #14

    well my cardboard ran me $6 per sheet and I needed 3 sheets for 2 buckets. not far off from your styrene cost at all.
    I am a bit worried about using cyano acrylic glue (superglue) over such large areas.
    I got a good hit off fumes just gluing on my ears. **** stuff burns up my eyes and nostrils.
    Big thing for me is the fact that it won't need near the amount of bondo work that cardboard needed.
    It's been 3 or 4 weeks now and I'm just now ready for Paint Tomorrow.
    Your build seems to have progressed much faster with styrene.
  15. TerranCmdr's Avatar
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    Oct 1, 2010, 11:38 PM - Re: Davehal9000's styrene helmets using WOF templates #15

    I'm sold on styrene too! I'm planning to do a biker scout build... a little more challenging in my opinion but I think the styrene should fit just fine. Thanks for the info!
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    Oct 18, 2010, 2:08 AM - Re: Davehal9000's styrene helmets using WOF templates #16

    Here's Boba, almost done. Just need to finish the range finder. Not the best, most accurate paint job in the world. Rushed things at one point and I think forgot a Dullcoat layer, causing quite a bit of paint to come off. Still, good enough for Halloween for a 8 year old







    Here's Jango. Silver, a visor and RF and he's done.



    Various other bits going with them...





    Last edited by Davehal9000; Oct 18, 2010 at 9:29 AM.
  17. Member Since
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    Oct 25, 2010, 3:59 PM - Re: Davehal9000's styrene helmets using WOF templates #17

    very nice ....like that you did both the boba and the jango
  18. Evilhemmes's Avatar
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    Oct 26, 2010, 6:29 AM - Re: Davehal9000's styrene helmets using WOF templates #18

    Quote jinstarkiller said: View Post
    very nice ....like that you did both the boba and the jango
    Aye mate great job allround very nice!

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