Before I post the details of my build I wanted to thank the dented helmet’s contributors for the wealth of source material that has been made available (free of cost) to an amateur hobbyist like myself. I respect the time and hard work that has gone into the creation of this source material and will in no way attempt to benefit from it financially. Any build I undertake is done solely for my own personal use and enjoyment.
hobby experience: Painting of miniatures (specifically world war 2), Model Making, Woodworking, fabrication, and I have created a Luke ANH lightsaber using a vintage Graflex 3 cell.
Professional experience: United States Army Veteran, Military Police Gunner/Driver, Technical Writer/Editor, Ground Tactical Vehicle Equipment Specialist/Subject Matter Expert.
I have been browsing various postings for a few days now and have gathered a lot of ideas and techniques from member contributions. If I post any information that should be rightfully credited to another member please let me know I will make sure to credit the content creator appropriately. Also, any advice or suggestions will be greatly appreciated.
The tools and resources I have at my disposal are:
Outdoor shop with general tools
Dremel Rotary Tool with press and routing table
Various small project hobby tools
I will be using WoL’s templates to create an aluminum sheet metal helmet. I haven’t decided on a final paint scheme yet but being an army veteran I am partial to the “OD Green” appearance of the ROTJ Helmet.
I have already started on the build by forming the helmet liner and fixing it together using JB Weld. My plan is to use three sheets of aluminum the first layer being the liner, the second layer and third layer will be using the mandible and earpiece template. Each layer will be fixed together using locktight epoxy.
Cutouts for the cheek bones won’t be attempted until the base of the helmet is formed and cutting out the visor will be the last step.
When I am ready to fix the cheek bones my plan is to have tabs that I will sandwich between the first and third sheets. The second sheet will be cut to provide clearance for the tabs.
I am still trying to decide whether I want to track down resin casts of the earpieces or if I want to attempt to fabricate them using sheet metal.
For the dome I am open to any ideas, I am leaving that bit for the end until inspiration finds me.
I will provide images later today on the projects progress.