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  1. ChrisTTB's Avatar
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    Feb 29, 2016, 11:57 AM - First attempt at ESB helmet #1

    Thought I'd share how my ESB helmet build is going, it's made out of picture mounting board 1.5mm thick as I couldn't find any 2mm board at my local hobby craft store, it has probably made it easier to cut and build but also means it's not as strong!
    I was thinking of using resin to strengthen it once I have done the filing.
    I will get some pictures up once I find out how to!

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  3. Gregory's Avatar
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    Feb 29, 2016, 12:33 PM - Re: First attempt at ESB helmet #2

    Looking forward to seeing it. I found my illustration board helmet flexible until I mounted the visor. Resin or fiberglassing the interior is sure to help.
  4. ChrisTTB's Avatar
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    Feb 29, 2016, 12:58 PM - Re: First attempt at ESB helmet #3

    Didn't think of doing the inside!
    Thanks for the help
  5. Gregory's Avatar
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    Feb 29, 2016, 1:34 PM - Re: First attempt at ESB helmet #4

    The pics show up now, looking great. I used plain old elmer's glue when I built mine. One trick that helps is to use glue to make a filet on the inside of a joint between two sections of board, when they join at some sort of angle. This is an old model rocketry tip.

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  6. syllander's Avatar
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    Feb 29, 2016, 10:24 PM - Re: First attempt at ESB helmet #5

    Looking good so far man!
  7. Mar 1, 2016, 7:32 AM - Re: First attempt at ESB helmet #6

    Clean build
  8. ShortFuse's Avatar
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    Mar 1, 2016, 10:54 AM - Re: First attempt at ESB helmet #7

    Looks good. The only thing I would have done differently is not cut out the visor area yet. It weakens the structure of the helmet. You are going to be doing a lot of sanding once you get the bondo on the dome and cheeks and you might bend it up more easily. You can always add a layer on the inside to strengthen it for now and then cut it out later.
  9. ChrisTTB's Avatar
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    Mar 1, 2016, 3:39 PM - Re: First attempt at ESB helmet #8

    Thanks Gregory, i have hot glue filleted every joint i can find, certainly works.

    ShortFuse, i am going to add another layer to the outside as i'm not happy with the thiickness of the rim of the helmet, its probably due to using thinner board, i wont be cutting out the visor on that piece this time.

    Thanks for all the kind and helpfull comments will post some more pictures once i have made some progress.
  10. ryan101011's Avatar
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    Mar 3, 2016, 8:17 PM - Re: First attempt at ESB helmet #9

    Look great! To add onto short fuse, I screwed a metal strip accross my chin area, helps a lot, also makes installing the visor a lot less scary.
  11. ChrisTTB's Avatar
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    Mar 4, 2016, 9:15 AM - Re: First attempt at ESB helmet #10

    Ryan - sounds like a good idea, wondering what to use for the visor as I can't seem to find any black tinted face masks here in the UK, perhaps I'm looking in the wrong places!
    Any help is greatfully recieved
  12. ChrisTTB's Avatar
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    Mar 29, 2016, 12:31 PM - Re: First attempt at ESB helmet #11

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    A few pics of my progress, dome needs one more coat of filler in places, painted inside with resin, filled and sanded cheek areas.
    Slow progress but want to get it right!
  13. Gregory's Avatar
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    Mar 29, 2016, 2:52 PM - Re: First attempt at ESB helmet #12

    Looking great! What kind of filler are you using, bondo?
  14. ChrisTTB's Avatar
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    Mar 29, 2016, 4:43 PM - Re: First attempt at ESB helmet #13

    GT Pro superfine car body filler, probably the UK equivalent to bondo

    - - - Updated - - -

    I think my dent is slightly in the wrong place, I'm thinking it should be more to the right looking at the front of my bucket, what does everyone else think?
  15. Member Since
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    Mar 29, 2016, 5:09 PM - Re: First attempt at ESB helmet #14

    Try these for smoked acrylic sheet, 3mm thick a4 pieces for under 5!
    Dark Smoked Grey Tinted Perspex Acrylic Plastic Sheet Cut to Size Tint Cast | eBay
  16. ChrisTTB's Avatar
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    Mar 30, 2016, 4:47 PM - Re: First attempt at ESB helmet #15

    Thanks Bobawannabe, now in my watching list.
  17. ROYSTERONE's Avatar
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    Mar 31, 2016, 3:23 PM - Re: First attempt at ESB helmet #16

    Looking great ,can't wait to see the final results.
  18. ChrisTTB's Avatar
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    Nov 5, 2016, 8:49 AM - Re: First attempt at ESB helmet #17

    Not been on for quite a while as I have been really busy over the summer, anyway have made some progress with my bucket so here are the picsClick image for larger version. 

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    Decided to go ROTJ instead of ESB after looking at the painting posts (I'm not that good at painting) I thought my bucket might finish up looking better with a simpler colour scheme!
  19. FandagoFett's Avatar
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    Nov 5, 2016, 7:30 PM - Re: First attempt at ESB helmet #18

    I'm interested in how this come out
  20. Member Since
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    Nov 7, 2016, 8:13 AM - Re: First attempt at ESB helmet #19

    That's a lot of work! Good job! I'm struggeling with the paintjob on my helmet.
  21. Grimstuff's Avatar
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    Nov 8, 2016, 3:43 AM - Re: First attempt at ESB helmet #20

    Quote ChrisTTB said: View Post
    I think my dent is slightly in the wrong place, I'm thinking it should be more to the right looking at the front of my bucket, what does everyone else think?
    You might be right, it does seem a bit left-ish to me, but it's hard to tell though with the helmet whited out and the angles of the photos.

    Best way to find out I found after a lot of fretting over dent placement myself is to find some reference shots of dead-on front and side angles, then try to replicate those shots yourself. Then view them all side by side and see how it looks.
  22. ChrisTTB's Avatar
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    Nov 8, 2016, 5:30 AM - Re: First attempt at ESB helmet #21

    Thanks for the help Grimstead much appreciated
  23. ChrisTTB's Avatar
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    Nov 8, 2016, 5:34 AM - Re: First attempt at ESB helmet #22

    Quote GodfatherFenix said: View Post
    That's a lot of work! Good job! I'm struggeling with the paintjob on my helmet.
    I'm going the airbrush route and I've never airbrushed anything before so there will be lots of practicing before any paint is applied to my bucket!
  24. ChrisTTB's Avatar
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    Dec 9, 2016, 2:22 PM - Re: First attempt at ESB helmet #23

    Been doing some work on my range finder, here are the pics so far
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    I used a 1hz and 2Hz ic's to flash the 2 red Leds it has an on/off switch and a tilt switch I also managed to squeeze in a charging port for the 3.7v lipo battery and all without having to hollow out the clear plastic part (not in pictures as it's not finished yet!)
  25. ChrisTTB's Avatar
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    Dec 17, 2016, 8:58 AM - Re: First attempt at ESB helmet #24

    Well I finally plucked up the courage to start painting my bucket, done the main damage and colour on the dome and lower cheeks so far, here are some pics
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    It may not be absolutely screen accurate but I'm happy with my first ever use of an airbrush
  26. ChrisTTB's Avatar
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    Dec 17, 2016, 11:23 AM - Re: First attempt at ESB helmet #25

    Kill stripes are next, masked them up, just need to liquid mask the damage then they can be airbrushed
    Click image for larger version. 

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