Subscribe
  1. Prymer13's Avatar
    Member Since
    Apr 2003
    Posts
    1,090
    Oct 11, 2004, 9:43 AM - DP 95 Vinyl reshaping problems #1

    Hey guys, I got a DP 95 that I have been pouring my free time into. I have finally worked thru the cutting, cleaning, and sanding of the exterior. I was about to start cleaning up the interior so I could build up the mandibles and get it ready for my visor.

    The guy I got the bucket from told me I could reshape it with a common hair dryer and then hold it into place until It cooled. WELL...I tried it several times. Then I overheated the hair dryer (I didn't know you could do that...).
    THEN I tried heating it up, pulling it into shape and dipping into cold water. I thought this was going to be it...yet it wasn't.

    I am about ready to break out my heat gun, but I am afraid it will leave me with a Fett shaped puddle.

    Any help and insight would be greatly appreciated.
    Darren
  2. EVO3's Avatar
    Member Since
    Apr 2004
    Posts
    108
    Oct 11, 2004, 10:52 AM - Re: DP 95 Vinyl reshaping problems #2

    Im going throught the same thing myself. Ive heard of some people installing a metal rod around the bottom rim of the helmet. Im gonna try doing the same thing but with some slim aluminum extrusion. Im just wondering if CA glue would hold it in place. Otherwise, i guess it could be screwed on with a few screws and then putty in the screw heads. Im gonna work on it tonight and see how it works out. I'll let you know.
  3. Geo's Avatar
    Member Since
    Aug 2003
    Posts
    1,011
    Oct 11, 2004, 10:57 AM - Re: DP 95 Vinyl reshaping problems #3

    Hey , if all else fails.... try Liquid Nails!
  4. Jodo_Kast's Avatar
    Member Since
    Sep 2003
    Posts
    1,589
    Oct 11, 2004, 11:57 AM - Re: DP 95 Vinyl reshaping problems #4

    When I got my DP95 it was the same story. I lessened the warp but it always came back to one degree or another.

    I took a piece of steel from the scrap at work and bent it with my superhuman strength until it BARELY fit along the bottom back edge of the helmet. Then I filled the sink with straight hot water (this is gentler and safer than using a heat gun) and soaked the bucket for a minute. I then used some padded (use a super soft hand towel) clamps to hold the steel tight against the helmet edge. Soaked it in cold water and then left it clamped up over night. The remaining warp after removing the steel was very minute.

    Hope this helps a bit.
  5. Prymer13's Avatar
    Member Since
    Apr 2003
    Posts
    1,090
    Oct 11, 2004, 12:16 PM - Re: DP 95 Vinyl reshaping problems #5

    IT does help... I was hoping that I was not going to have to use my superhuman strength (I mainly use it for fighting evil). But if I must, then I must.

    My only concern is that I have already cut out the visor and I would think that no matter how I chose to reinforce this area, that I would be a weak spot.
  6. cal196's Avatar
    Member Since
    Aug 2004
    Posts
    2,617
    Oct 11, 2004, 1:46 PM - Re: DP 95 Vinyl reshaping problems #6

    you need a good hair dryer, and you need to heat it up really hot to the point of almost melting. It needs to be supersoft where you want it to bend, and at the other point your trying to bend it to. for instance if the back is warped to one side you need to heat the side of the back where its warped and the other side where you want to straiten it out, otherwise there is nowhere for the warp to go but back to its original shape.
  7. T-Bone's Avatar
    Member Since
    Jun 2003
    Posts
    965
    Oct 11, 2004, 1:51 PM - Re: DP 95 Vinyl reshaping problems #7

    I attached my welding visor to my helmet with "Plastic Welder". I found it at Walmart with the other glues. It is a 2 part epoxy, and comes in an applicator which allows you to push both portions out at the same time.

    This stuff really works. It actually melts the plastic together as it dries. And it is dry in about 15 minutes. I used to have hot glue in to hold it, but this stuff really helps hold it together...and makes it easier for you to re-shape the bucket.

    I set my bucket in the sun most of the day (of course this was back in the summer and I'm in Alabama so it's good and hot here!). After it was good and warm, I placed a wooden dowel inside, width-wise in the helmet, the length of which made it flare MORE than I really wanted to be flared. Then I stuck it in the fridge the rest of the day.

    It seemed to work, but It seems as time goes by it tend to flatten back, so I keep the dowel in it when I'm not wearing it.

    You can buy a metal hoop at Walmart, which you can cut and place inside on the back. This can also help keep it flared out. I bought one the other day, but haven't gotten it installed yet.

  8. fett-uk's Avatar
    Member Since
    Sep 2002
    Posts
    369
    Oct 11, 2004, 6:16 PM - Re: DP 95 Vinyl reshaping problems #8


    EVO3 wrote:

    Ive heard of some people installing a metal rod around the bottom rim of the helmet. Im gonna try doing the same thing but with some slim aluminum extrusion. Im just wondering if CA glue would hold it in place.
    thats the method i used for my DP97 and DP 95, hot glue worked fine holding the rod in place.

    Fett-UK

  9. Prymer13's Avatar
    Member Since
    Apr 2003
    Posts
    1,090
    Oct 11, 2004, 6:21 PM - Re: DP 95 Vinyl reshaping problems #9

    Thanks for the input guys, now this metal rod, what diameter are we talking about? And what material?

    Finally, should I bend the rod to be more oblong, or perfectly round?

    (I am planning a trip to LOWE's soon, so a fast reply will definately help.

    Thank you
    Darren
  10. bobafett669's Avatar
    Member Since
    Jun 2004
    Posts
    988
    Oct 11, 2004, 6:42 PM - Re: DP 95 Vinyl reshaping problems #10

    Put in hot car for a few minutes, 10 or 15 minutes on a hot day. It will get real soft. Shape. Place a towel inside helmet to hold the sahpe you want and quickly put in the FREEZER, not the fridge. It will hold the shape and then you can strengthen it with whatever you want to. I am going to use a brass craft circle from Wal-Mart that I cut with the dremel and bent to the shape I want it to hold. I will install it around the bottom this week. Mine has held the freezer shape for over 2 months now.
  11. fett-uk's Avatar
    Member Since
    Sep 2002
    Posts
    369
    Oct 12, 2004, 2:46 PM - Re: DP 95 Vinyl reshaping problems #11

    I picked up the rod from work so not sure of the material, but its very tough NOT ALUMINIUM. I bnt it round making the length from ear to ear 9" which looks OK to me, anymore is pushing it I think.
    Hope this helps, i will get some pics of the inside of my bucket is thats any use!
    Good luck

    Jon
  12. Duh
    Guest
    Oct 13, 2004, 5:11 PM - Re: DP 95 Vinyl reshaping problems #12

    To reshape my helmet I used the "metal rod" as well. Its not actually a mental rod. It is a metal ring that is used for sewing/crochette (SP?). You can find them at Michael's. I used a Dremel and cut the ring in half so that it would fit inside the back of the helmet where it was needed. I heated the helmet and used a glue gun to attach the metal ring. Worked like a charm.

    Here are some pics of the finished product...

    http://members.cox.net/debnwar/helm5.JPG
    http://members.cox.net/debnwar/helm6.JPG
  13. Prymer13's Avatar
    Member Since
    Apr 2003
    Posts
    1,090
    Oct 27, 2004, 10:30 AM - Re: DP 95 Vinyl reshaping problems #13

    Well, after much looking and NO finding I tried something...I found a 9" wooden cross stitch hoop that I clamped on the inside and tried heating it and leaving it clamped up.

    I have had it in clamps for days now, and last night I used the 'ol hair dryer on it three times leaving it clamped thruout...BUT my wife's cheap little white hair dryer kept over heating and cutting out. SO tonight I am breaking out the BIG guns and bringing my heat gun home. I am going to make sure that I don't over do it and keep it moving, but IT WILL BE SHAPED correctly tonight!

    Update to follow
    Darren

  14. cal196's Avatar
    Member Since
    Aug 2004
    Posts
    2,617
    Oct 27, 2004, 10:42 AM - Re: DP 95 Vinyl reshaping problems #14

    That should do it. keep the sink full of cold water, when it melts and you bend it, dipping it into the water should freeze it in that position. aint it funny how it can warp outta shape in 3 seconds in a car and stay in that exact shape forever! but 2 hours of heating it up and getting it strait and it pops back into the same shape it was 3 days later. I dont get it.
  15. Prymer13's Avatar
    Member Since
    Apr 2003
    Posts
    1,090
    Oct 27, 2004, 11:03 AM - Re: DP 95 Vinyl reshaping problems #15

    I don't get it either...if this doesn't work I am going to scour the earth for that stupid 9" wire cross stitch hoop, and when I find it, I am going to heat this vinyl helmet until it's almost a puddle! J/K....

    But if it doesn't work, I am usin the metal hoop, and using superglue and bondo to install it permanently.

    And reguardless of how well this does or doesn't go...I am keeping Marrow-Sun's e-mail clsoe by. i am not going thru this again.

    Darren
  16. cal196's Avatar
    Member Since
    Aug 2004
    Posts
    2,617
    Oct 27, 2004, 11:15 AM - Re: DP 95 Vinyl reshaping problems #16

    lol no kidding. I cant wait to upgrade to glass.
  17. ChurchBlue
    Guest
    Oct 27, 2004, 4:46 PM - Re: DP 95 Vinyl reshaping problems #17

    Have any of you tried making a full metal fram inside not just a ring or bar?
  18. Prymer13's Avatar
    Member Since
    Apr 2003
    Posts
    1,090
    Oct 27, 2004, 11:37 PM - Re: DP 95 Vinyl reshaping problems #18

    Church, I had thought of it, and that was going to be my last ditch attempt...however:

    Temperature that water freezes: 32 F
    Temperature of the average human body: 98.6 F
    Temperature that paper catches fire and burns: 451 F
    Temperature that melts a Vinyl DP95 so it can be successfully reshaped: 1000 F

    Ok, so it wasn't constant, but thats the measured output of my Bosch Heat Gun. It took three attempts, one wooden hoop frame, three spring clamps and an "ice bath", but I have finally reshaped my bucket to what I deem acceptable.

    NOW I can finally finish trimming and priming it!!!
    Thanks to all for your input and support.
    Darren
  19. ACSS2's Avatar
    Member Since
    Mar 2004
    Posts
    245
    Oct 29, 2004, 4:51 PM - Re: DP 95 Vinyl reshaping problems #19

    I just used a metal ring to reshape mine.
  20. sarlac_snack
    Guest
    Nov 5, 2004, 8:18 AM - Re: DP 95 Vinyl reshaping problems #20

    Can someone post some photos of the metal ring/hoop mounted inside the helmet? I'm a visual person and would need to see it in order to do it, lol. I am trying to fix a HEAVILY warped (but nicely flared) DP97. Pics available here:

    http://tdh.prop-planet.com/viewtopic...=11790&forum=2
  21. fett-uk's Avatar
    Member Since
    Sep 2002
    Posts
    369
    Nov 5, 2004, 3:32 PM - Re: DP 95 Vinyl reshaping problems #21

    Heres a few shots of my DP95 and 97 not sure if its clear enough for you but hope it helps


  22. sarlac_snack
    Guest
    Nov 5, 2004, 10:32 PM - Re: DP 95 Vinyl reshaping problems #22


    fett-uk wrote:

    Heres a few shots of my DP95 and 97 not sure if its clear enough for you but hope it helps
    That is exactly what I needed. Well, I will attempt to do this this weekend and let you know the results. Thanks again.
  23. fett-uk's Avatar
    Member Since
    Sep 2002
    Posts
    369
    Nov 6, 2004, 5:31 PM - Re: DP 95 Vinyl reshaping problems #23

    glad to be of help....just looking at my pic...has anyone else noticed how photos make your flightsuit looks soooooo clean.
    But I think gotta dirty it up some more though.
  24. T-Bone's Avatar
    Member Since
    Jun 2003
    Posts
    965
    Nov 15, 2004, 9:12 PM - Re: DP 95 Vinyl reshaping problems #24


    sarlac_snack wrote:

    Can someone post some photos of the metal ring/hoop mounted inside the helmet?
    Here are a few of mine. I finally got it installed this weekend. I ran out of the plastic welding glue, but I believe it will hold. I'm going to get another tube and place a bead of glue on the inside, top edge to firm it up more.

    Here is the a shot of the back from the inside.


    I took the ring and cut it to fit between the depresions on the inside from the ears.


    I like the flare now.


    And while I'm at it...here's one from Halloween.


    [edit]
    Had a few questions asked about the glue I used. I rescued the old tube from the trash can so I could get the info off of it.

    Name - the "Plastic Welding System"
    Maker - ITW Products
    Where - Can be purchased at Wal-Mart, HD, or Lowes
    This is an epoxy type glue which you have to mix. Comes in a black, dual syringe tube. Use outdoors only has a very LOUD smell to it. This stuff really works on plastic. Not only does it stick the stuff together, it sort of welds it. I have also used it on sticking metal to plastic (I.E. like the helmet, and on my JP) and it works real good.

    If you give it about 2 days to dry, it becomes very hard and is sandable as well. I used this stuff when I was putting my JP together. It really made good hard seams.
    [/edit]


Similar Threads

  1. Reshaping fibreglass armour
    By Dougie Fett in forum Boba Fett Costume
    Replies: 7
    Last Post: Jul 8, 2008, 10:50 AM
  2. Vinyl vest
    By CodytheSeparatist in forum Boba Fett Costume
    Replies: 4
    Last Post: Dec 17, 2005, 11:09 AM
  3. Reshaping Fiberglass
    By asok in forum Prop Building Workshop
    Replies: 5
    Last Post: Dec 3, 2005, 6:09 PM
  4. Visor Reshaping
    By Pooper in forum Jango Fett Costume
    Replies: 16
    Last Post: Jun 25, 2005, 8:13 AM