Jango 2-piece injection helmet conversion to Boba ESB

@elusivesolution Thanks so much! I went and checked out your Jango deluxe conversion...SWEEEEEEEEET, man! I had so much fun doing this that I'm going to do a helmet for myself. I'm going to convert the Jango Deluxe.
 
I'm glad you liked my bucket. I've never actually handled the 2 piece in real life but it looks to be about the same size, perhaps a teensy bit smaller than the deluxe. Have you had the chance to compare the 2? Also, did you use the ESB helmet templates that are available on the board or did you free hand the damage? It looks killer.
 
@elusivesolution I've never handled the Jango deluxe before so I'm not really sure. Just from looking at both they seem like the same size but I think the 2-piece is slightly longer from front to back. The back panel weathering and dome scratches I used the stencils because they were big enough areas to place the cut out stencils to trace. As for the rest of the helmet (mandibles, upper & lower cheeks, keyhole slot) all was done free-hand because there was so little room to place a stencil pattern to trace.

Here are the measurements of the helmet. Just so you're aware, both L & R earcaps are hallow with no back wall and the RF stalk comes backwards if you're planning to get one.

FILE0081.JPG


018.JPG
 
This was my sons first helmet as well... You can cut the right ear apart to make it into two pieces. For the goofy stalk, trace the old one and add length to it, then just cut a new one. I wish when I did his, that I would have cut out the lower cheeks to make them flat. The curved cheeks just look off.
 
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@elusivesolution I've never handled the Jango deluxe before so I'm not really sure. Just from looking at both they seem like the same size but I think the 2-piece is slightly longer from front to back. The back panel weathering and dome scratches I used the stencils because they were big enough areas to place the cut out stencils to trace. As for the rest of the helmet (mandibles, upper & lower cheeks, keyhole slot) all was done free-hand because there was so little room to place a stencil pattern to trace.

Here are the measurements of the helmet. Just so you're aware, both L & R earcaps are hallow with no back wall and the RF stalk comes backwards if you're planning to get one.
At what percent did you print off the stencil patterns?
 
I copied and pasted the stencils to MS Paint and enlarged it through trial and error to get the right size. You can manipulate the size of the the image you paste by dragging the r & l side or the 4 corners inward or outward to increase or decrease the size.
 
Had to get this helmet delivered to my Aunt in Cali and then delivered by my Aunt to the UK when she visited last month. Looks good considering. Your work tho looks epic! Well done! If mine turns out half as good I'll be well excited.
Especially as my head barely fits in my Don Post lol!
 
@MisterHyde I just wanted to say wow! I want to do this and you have really inspired me, one question though, where did you purchase the original 2 piece helmet from? I live in the UK and cannot find it anywhere for less than $100 :( It would be cheaper for me to buy it from the US including shipping. All help greatly appreciated.
 
I have to say, it's AWESOME! Im using your brilliant idea to make my jango bucket into a beautiful ESB boba fett, for a complete costume. Did the foam padding inside help the helmet? I'm just scared it's going to crack because of the flimsy plastic, I bondoed the dome and the gaps between the ear peices, and the seam lines, but the checks are scaring me. I'm tempted to fiberglass the inside to help the strength, but idk yet.
 
I have to say, it's AWESOME! Im using your brilliant idea to make my jango bucket into a beautiful ESB boba fett, for a complete costume. Did the foam padding inside help the helmet? I'm just scared it's going to crack because of the flimsy plastic, I bondoed the dome and the gaps between the ear peices, and the seam lines, but the checks are scaring me. I'm tempted to fiberglass the inside to help the strength, but idk yet.
As far as making the helmet more rigid, the padding doesn't really help. It's really for making sure the helmet doesn't move around when you put it on. I suggest that you use gorilla tape on the inside gap all the way around like I did in the picture. Don't worry, you're using bondo which is really strong. And once you put the right and left ear pieces on and the t-visor the helmet will be sturdy. I hope that helps. Have fun with your project...cheers!!!
jango-2-piece-injection-helmet-conversion-boba-esb-file0081-jpg-46083d1283129270
 
As far as making the helmet more rigid, the padding doesn't really help. It's really for making sure the helmet doesn't move around when you put it on. I suggest that you use gorilla tape on the inside gap all the way around like I did in the picture. Don't worry, you're using bondo which is really strong. And once you put the right and left ear pieces on and the t-visor the helmet will be sturdy. I hope that helps. Have fun with your project...cheers!!!
http://www.thedentedhelmet.com/atta...ersion-boba-esb-file0081-jpg-46083d1283129270

thanks again, my painting probably wont be as good as yours, but hopefully some what nice.
 
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