davidFett's '95 Don Post Redux

Trying to meet my 5 post ''new member'' requirement, so I thought I'd post my first ESB Helmet build.

I'm a long time prop builder/collector, but this is my first attempt at the Boba Fett ESB Helmet.

Decided to start off with the ESB Hero Version... the paint job, to me, is a little more appealing. I plan on following up this build with both ROTJ and SE version Helmets.

Starting off with this '95 Don Post I found on eBay.



I thought this one had a decent enough profile... not too badly ''flattened'', as the later Don Post helmets seem to be. A bit smaller than other versions (fettpride, bobamaker, etc.), but that was to be expected.

The seller claimed only minimal damage to the visor... Well, I need to remove and replace the visor anyway, so no problem. I took a chance and went ahead and bought it.

The Helmet arrived and appeared to be in good condition. I think I can work with this.

davidFett

First I removed what was left of the plastic visor. Using my Dremel Tool with a cutting disc, I removed the t-shaped "visor" using care not to remove the red portion of the mask.
I trimmed the excess with an x-acto knife, a bastard file and 200 grit sandpaper until I had a nice clean edge.



A bit more cleanup and the helmet should be ready for a new t-visor.

I'm also noticing the bottom of the helmet is a bit crooked and should be flared out a bit more.

I think I can straighten it by using a metal crochet loop, cutting it in half and gluing it along the contour of the back of the mask. This should also help prevent warping in temperature changes and keep the visor in place.

davidFett

I purchased a "Standard" laser cut T-Visor here.



The "Standard" version fits both Don Post and Rubies Helmets as well as others.

Initially I had thought of using epoxy to attach the visor, but Spideyfett's method seems like the way to go.

davidFett

Only one more post to go...

davidFett

Thanks for the tips, everyone.

Decided to have a look at RafalFetts stencils, since those seem to be the templates of choice…

…and thanks for looking at my build!

davidFett

I'm starting to gather up all the bits and pieces I'll be needing…

I did manage to find the 3-hole Borden connector this morning... found one at a local dental supply store.



Also looking at bobamaker's Deluxe Hollow Rangefinder and RF stalk – these look to be of excellent quality, but are a couple of months out on backorder... and for the most part, seem to be cast in resin.

I'd prefer Aluminum rangefinders, but these seem to be of excellent quality.

More to come, time permitting...

davidFett