davidFett's '95 Don Post Redux

  1. #1

    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.

    tdh_95_dp_ebay_02-jpg

    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
    Last edited by davidFett; Dec 10, 2012 at 3:10 PM.

  2. #2

    Re: davidFett's '95 Don Post Redux

    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.

    tdh_t-visor_prep_03-jpg

    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
    Last edited by davidFett; Dec 9, 2012 at 8:04 AM.

  3. #3

    Re: davidFett's '95 Don Post Redux

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

    std-jpg

    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
    Last edited by davidFett; Dec 18, 2012 at 7:40 PM.

  4. #4

    Re: davidFett's '95 Don Post Redux

    Next up I need to remove the key slots on the rear of the helmet then I'll knock down this paint job with some 200 grit sandpaper.

    Once the prep work is done I plan to use Rich D's ESB stencils and templates for painting.

    Stay tuned…

    davidFett

  5. #5

    Re: davidFett's '95 Don Post Redux

    Only one more post to go...

    davidFett
    Last edited by davidFett; Dec 7, 2012 at 12:56 AM.

  6. #6

    Re: davidFett's '95 Don Post Redux

    POST #6!

    Hope that does it...

    davidFett

  7. #7
    girlattorney's Avatar
    Member Since
    Oct 2012
    From
    Portland, Oregon, United States
    Posts
    61

    Re: davidFett's '95 Don Post Redux

    Looks good! I added some fiberglass to the inside of mine after reshaping it, holds it's shape very nicely now. I highly recommend using Spideyfett's visor method, having a removable visor can be handy. I would have had some trouble if I had glued mine in.

  8. #8
    Jayvee's Avatar
    Member Since
    Sep 2010
    From
    Perth, Western Australia
    Posts
    640

    Re: davidFett's '95 Don Post Redux

    I would highly reccomend Rafalfetts templates. For ESB, his templates are about as accurately perfect as you can get. We don't call him 'Captain Precision' for nothing! Good luck with the build my friend- that Don Post actually looks in pretty good shape

  9. #9
    StrumFett's Avatar
    Member Since
    May 2008
    From
    France
    Posts
    213

    Re: davidFett's '95 Don Post Redux

    Hi,
    I agree with Jayvee. RafalFett templates are the best ones IMHO.

  10. #10
    RafalFett's Avatar
    Member Since
    Oct 2010
    From
    Galati, Romania
    Posts
    2,634

    Re: davidFett's '95 Don Post Redux

    Jayvee said: View Post
    I would highly reccomend Rafalfetts templates. For ESB, his templates are about as accurately perfect as you can get. We don't call him 'Captain Precision' for nothing! Good luck with the build my friend- that Don Post actually looks in pretty good shape
    Thanks for the support! But because davidFett wants to paint the ROTJ SE suit, the best option is to follow Rich D.'s stencils (because of the extra scratches) and use my stencils for the rest of the parts (the dome and the ears). But the decision belongs to him...

    StrumFett said: View Post
    Hi,
    I agree with Jayvee. RafalFett templates are the best ones IMHO.
    Thanks for the kind words!

  11. #11

    Re: davidFett's '95 Don Post Redux

    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
    Last edited by davidFett; Dec 9, 2012 at 8:43 AM.

  12. #12

    Re: davidFett's '95 Don Post Redux

    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.

    tdh_borden_3-hole_01-jpg

    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
    Last edited by davidFett; Dec 18, 2012 at 7:43 PM.

  13. #13
    dynamic1's Avatar
    Member Since
    Oct 2010
    From
    Murrieta Ca.
    Posts
    1,166
    I love this lid..great find man and good luck!
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