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  1. saltydog81's Avatar
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    Apr 27, 2008, 3:40 PM - don post helmet update #1

    keep checking back i will continue to post pics of my progress
    ok my cruddy camera broke so i used my roommates...

    i found this dp '96 on craigslist and bought it
    it was still in the box with its tag and all (mint)


    so i took a look to see if there were any areas that would need fixing...
    first the cheep visor had to go.


    then i looked for bubbles in the plastic this pic here is 1 of maybe 5 areas i saw.


    then areas that would need cutting out.



    then areas that would need fill ... besides the dent
    there were two such factory stamps


    and lastly i checked the shape

    if you look closely the top of the dome is a bit out on the bottom left
    but the worst part is the rest of the shape .... which can be seen the best from below..


    so i plan to make a inner support out of plywood and barrow a heat gun to reshape this. the support is purely to get the shape right then i will remove it.

    i think this will shape up to be a better start for me than my rubbermade brute distaster and with some time and alot of work i think i could make a great helmet out of this
    Last edited by saltydog81; Apr 27, 2008 at 10:59 PM.
  2. Dabbafett's Avatar
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    Apr 27, 2008, 3:54 PM - Re: don post helmet update #2

    cant wait to see the modifications!
  3. Member Since
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    Apr 27, 2008, 3:58 PM - Re: don post helmet update #3

    Dude i found that with post/rubies helmets that a dremel tool is gonna be your best friend.
  4. tubachris85x's Avatar
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    Apr 27, 2008, 4:15 PM - Re: don post helmet update #4

    I just want to say that using a heat gun wont do anything to it. Your going to need to fix a permant attachment to keep the proper shape. A member used a curved metal tube/pipe and attached it to the bottom inner part of the helmet, and it retains it's shape. Just letting you know to save you time. I had a rubies, made of the same vinyl and didnt change shape for anything.
  5. saltydog81's Avatar
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    Apr 27, 2008, 4:27 PM - Re: don post helmet update #5

    Your going to need to fix a permant attachment to keep the proper shape. A member used a curved metal tube/pipe and attached it to the bottom inner part of the helmet, and it retains it's shape.
    noted ... i read a thread about someone doing that thanks

    Dude i found that with post/rubies helmets that a dremel tool is gonna be your best friend.
    i have a battery one that sux so i'm going to get a corded one soon.
    cant wait to see the modifications!
    i will post new pics as i work on it ... but like i said before my camera broke so my roommate will have to let me barrow his again

    thanks for the help guys.
    Last edited by saltydog81; Apr 28, 2008 at 10:13 PM.
  6. I helped at SDCC '08 GCNgamer128's Avatar
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    Apr 27, 2008, 5:05 PM - Re: don post helmet update #6

    You could just shape it using a hair drier, the heat gun may be way too hot for that.
  7. saltydog81's Avatar
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    Apr 27, 2008, 5:14 PM - Re: don post helmet update #7

    yah i was thinking that a craft ring like tubachris85x suggested and try a heat and quick cool combo like i have read about... as for the heat gun i dont plan to have it too close and i would be monitoring how hot i got it
  8. Bubba Fett's Avatar
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    Apr 27, 2008, 5:15 PM - Re: don post helmet update #8

    I used a craft ring and hot water to get the shape.
  9. saltydog81's Avatar
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    Apr 27, 2008, 7:08 PM - Re: don post helmet update #9

    I used a craft ring and hot water to get the shape.
    like near boiling water?
  10. Darasuum_Verd's Avatar
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    Apr 27, 2008, 8:40 PM - Re: don post helmet update #10

    Ah yes, there are a couple "bubbles" in the plastic like that on mine near/on the ears of my DP96 as well.

    As for the shape, mine isn't quite that.. off, but one of the previous owners probably worked on that.

    Anyway, it looks good! I can't wait to see it finished

    -Naas
  11. saltydog81's Avatar
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    Apr 27, 2008, 9:48 PM - Re: don post helmet update #11

    just killing time till the bondo drys pics will be up soon for my progress... i cut out more of the visor area but left some uncut for support till i get a new visor. removed the range finder and drilled some holes in the key slots then sanded off some of the god awful paint job. i bondo-ed the bubbles, the dent, the factory stamps, and some on the inside of the helmet at the range finder for support. i tried to make inner rings out of the wizard of flight templates out of plywood by making the patterns 1/4 inch smaller all around but the shape is so far off that, that idea didn't work out and i will be getting a craft ring for it another day.
  12. saltydog81's Avatar
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    Apr 27, 2008, 10:38 PM - Re: don post helmet update #12

    ok the bondo dried so heres some pics of my progress

    this is where i cut more of the visor out but not all yet

    removed the range finder i will be putting a boba maker on later

    a close up of the dent patch

    the first factory stamp

    and the other

    the biggest of the bubble patches

    the range finder re-enforcement on the inside

    the holes i drilled in the key slots... i will cut it out fully later

    and me trying it on lol
  13. saltydog81's Avatar
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    Apr 27, 2008, 11:35 PM - Re: don post helmet update #13

    ok its 9:30pm here so I'm done for the night but i will buy a craft ring or two tomorrow and some glue sticks. if anyone has tips or idea on how to make this helmet awesome feel free to let me know
  14. Member Since
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    Apr 28, 2008, 7:56 PM - Re: don post helmet update #14

    its lookin good man keep it up. are you going to cut out the key holes on the back.
  15. saltydog81's Avatar
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    Apr 28, 2008, 9:19 PM - Re: don post helmet update #15

    are you going to cut out the key holes on the back.
    yes i plan to do that im just waiting on a dremel which i will get friday.

    ok the next update...
    as you may recall this was the shape it came as... (shudders)

    so i added some craft rings and fixed it

    one up at the dome...

    and another at the bottom. both are hot glued on so in case you were wondering that black stuff is just glue nothing special. man that made all the difference didn't it

    heres a better pic of the new shape.

    ok this dome pic if you look closely i was sad to find that the key slot area is off center sadly i will have to dremel this and move it over later.
    next i decided i would primer the whole thing so i could better find the little areas that need more bondo or other corrections... there are many.

    you may notice it all looks a bit shiny... its still wet

    i sanded the range finder area alot there was a ton of glue built up there from the factory.

    well thats it for today and if any administrators are reading maybe they could re-title this to "fixing the don post '96"
  16. jawafive's Avatar
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    Apr 28, 2008, 10:27 PM - Re: don post helmet update #16

    Looking good! I am glad that you're having fun with it. I've painted a few DP buckets and always had a great time.

    -Matt
  17. saltydog81's Avatar
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    Apr 28, 2008, 10:35 PM - Re: don post helmet update #17

    Looking good! I am glad that you're having fun with it. I've painted a few DP buckets and always had a great time.
    thanks Matt

    well i couldn't leave it alone so here are some more pics

    i looked for areas that needed fill, smoothing out, or build up after primering it... which was to make it easier to see.

    this side isn't as bad

    still haven't messed with the keyslots

    this was the worst of it.

    and i just had to put it on my head again
    its kinda late so i will leave the bondo build up for tomorrow and i also plan to fiberglass around the craft rings to make them more permanent.

    with any luck this will be the end result.
  18. Darasuum_Verd's Avatar
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    Apr 28, 2008, 11:23 PM - Re: don post helmet update #18

    Wow, dude! That looks great!

    Um, just curious, how did you pop off the RF Top ear section? I'd like to know that bit ^.^

    -Naas
  19. Member Since
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    Apr 28, 2008, 11:28 PM - Re: don post helmet update #19

    awesome job on the shaping,
  20. saltydog81's Avatar
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    Apr 28, 2008, 11:30 PM - Re: don post helmet update #20

    Wow, dude! That looks great!
    awesome job on the shaping,
    glad you guys like it I'm much happier now that the awful shape is fixed.

    Um, just curious, how did you pop off the RF Top ear section? I'd like to know that bit ^.^
    happy to help Darasuum_Verd.... i carefully scribed down the line with a razor blade then put the stalk down and carefully pried with a small chisel till the glue gave.

    i just stopped by boba maker a second ago so i could drool over the gear... im going to be buying his visor and range finder to put on this helmet... maybe the circuit board too I'm not sure yet.
  21. tubachris85x's Avatar
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    Apr 28, 2008, 11:52 PM - Re: don post helmet update #21

    Good job! Those craft rings really gave it an awsome shape and flare!!
  22. Apr 29, 2008, 3:23 AM - Re: don post helmet update #22

    i got me a dp95 about 7monts ago, there pretty nice ,and very cool to work with. any question you have,just ask; everybody in this board is very friendly,and willing to share their skills. by the way welcome to this great board. oh and about the key holes, i wouldn't worry about it. looks good. -freddy
  23. saltydog81's Avatar
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    Apr 29, 2008, 2:41 PM - Re: don post helmet update #23

    i got me a dp95 about 7monts ago, there pretty nice ,and very cool to work with. any question you have,just ask; everybody in this board is very friendly,and willing to share their skills. by the way welcome to this great board. oh and about the key holes, i wouldn't worry about it. looks good. -freddy
    thanks Freddy i will be on later when I'm off work and i will probably have some more bondoing done and if i have any questions i will let you know first
  24. Dabbafett's Avatar
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    Apr 29, 2008, 2:55 PM - Re: don post helmet update #24

    looking really promising man!

    cant wait to see the end result
  25. Darasuum_Verd's Avatar
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    Apr 29, 2008, 5:30 PM - Re: don post helmet update #25

    saltydog81 said: View Post
    glad you guys like it I'm much happier now that the awful shape is fixed.


    happy to help Darasuum_Verd.... i carefully scribed down the line with a razor blade then put the stalk down and carefully pried with a small chisel till the glue gave.

    i just stopped by boba maker a second ago so i could drool over the gear... im going to be buying his visor and range finder to put on this helmet... maybe the circuit board too I'm not sure yet.
    Alright, thanks a lot ^.^

    Can't wait to see you helmet finished!

    -Naas

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