JoshCube's Scratchbuild Bucket Progress Thread

[joshcube]

Let my first words in this thread pay tribute to wizardofflight. Without his templates, I would not be attempting this. If my bucket turns out well, it's thanks to him, if it turns out like ****, then it's my fault.

I was waiting to start this thread until I had some pics to post, but I haven't had time to download them off my camera. I also didn't get as far as I had hoped last weekend. All I was able to do is cut the pieces out of the sintra sheet.

Last night I was grilling some steaks and I was looking at the grill and thinking about my bucket and.... you guessed it:

I grilled the bigger sintra pieces to heat them up to start shaping them.

Worked liked a charm, although I don't recommend actually placing them on the grill. Just hold it over the heat and bend it. I did lay one piece on the warming rack above the main grill and that left some grill marks, but it's where the keyhole slots are going to end up being anyway.

Here is a summary of my efforts thus far:

Version 1.00 (Concept abandoned):

• Sterilite trashcan ($10.99) - Cut and shaped the pieces only to find out that polypropylene plastic doesn't glue well.

Version 1.01 (Dome concept abandoned):

• 4'x4' 4mm thick sintra sheet with part of a sign glued to it (free - out of a dumpster behind a sign shop) - only about 2.5'X1' actually needed for the main helmet pieces
• Toy batting helmet from Toys R Us for the dome ($2.50) - Turned out it's made of polyethylene (the "other" plastic that resists glue).

Version 1.02 (in progress):

• Same sintra pieces from 1.01 - Glue will not work on side with the sign even after the sign was peeled off. Will have to sand down inside surfaces that need to be glued.
• Dome will probably be scratchbuilt.
• Templates were modified so that the "inside surface" plate glues behind the ear pieces (no seam in the back). This also seems to have the nice effect of flaring out the sides a little. Next time I will modify the template to put the seam for the "trim" behind the right earpiece as well.

Version 1.02 Investment to Date: $5.99 (for Bondo)
Total Project Investment (including failed attempts): $19.48

Pics to come!

[3720to1]

Cant wait to see it!

[joshcube]

Here are some pics finally...

The prize rescued from the dumpster:



Templates laid out and traced:



Pieces I cut and then shaped with the BBQ:



In the above pics you can see how I taped the "inside surface" template together in the back and then cut it where it goes behind the ears so that it won't have a seam in the back.

[tubachris85x]

Its looking great so far, the shape looks awsome. Keep it up, and your gonna have a great helmet soon. Show us more!

-tubachris

[joshcube]

After a couple hours of sanding and using "Goo Gone" I was finally able to get the spray adhesive backing off of the inside surface of the helmet front to prepare it for gluing.

Anyway, I glued the front and back together last night. I tried superglue because it tested super strong. If you look in the one pic you can see where I cut the corner off the sheet and glued it face to face. The bond was strong enough to pick up the entire sheet off the ground without breaking.

Unfortunately, it's really hard to use it over a large surface. The result was a strong bond in just a few spots and lots of visible gaps. So, I tried epoxy on the other side and that worked better, but even after curing overnight it feels like I could break the bond with just a little force.

I'm going to Home Depot at lunch today to pick up some PVC pipe cement and give that a try. I want something that is going to effectively laminate the "trim" to the rest of the helmet so that I can eventually sand it down for that nice rounded edge appearance. I will take pics of my progress this weekend although I don't expect to get to the dome at all.

I also found a really exhaustive guide to working with Sintra. Enjoy:

http://www.piedmontplastics.com/stat...o%20Manual.pdf

[never_ending_fett]

I got a good chuckle out of the sign...my only question is does it break the new profanity rule?

great start on your scratch build

[joshcube]

Finally uploaded some more pics:





I had a lot of trouble with the gluing the cheeks and finally got impatient and just gooped them up with Bondo really thick. It looks nice on the outside, but the inside is pretty ugly.

I then ran into some problems with the bondo "cracking" away from the joints with the sintra where it meets the T-visor. This was finally solved last night after I learned a great trick for pouring baking soda on top of super glue. It makes the superglue cure right away and also makes a filler for cracks. I also reinforced the joints with epoxy on the inside.

[tubachris85x]

Looking great so far. As what they say, "its the outside that counts..." or is it the other way around? Awell, dosnt matter too much. Keep it up!! You know when you did an outstanding job when you pass out from the epoxy fumes! Like I did at one point....Thats another story for another day...

-tubachris

[Bubba Fett]

Great work so far. Always amazed by what some people can do with some inexpensive materials, creativity and determination.

[Jango 5204]

I always bought a thick, gap filling CA glue and sprayed it with the instant set.

[joshcube]

I always bought a thick, gap filling CA glue and sprayed it with the instant set.

Instant Set: $6.39 a can*
Baking Soda: $0.99 a pound*



*Plus or minus 30% depending on where you shop

[GCNgamer128]

I am very surprised at how well you got the cheek area cleaned up and smoothed out!! That's a great looking helmet What will you be using for the dome?

[kibosh]

This was finally solved last night after I learned a great trick for pouring baking soda on top of super glue. It makes the superglue cure right away and also makes a filler for cracks. I also reinforced the joints with epoxy on the inside.

Can you explain this in a little more detail? Are you saying you mix super glue and baking soda as a gap filler? Does it sand ok?

[joshcube]

I am very surprised at how well you got the cheek area cleaned up and smoothed out!! That's a great looking helmet What will you be using for the dome?

I don't know yet... I'm keeping my eyes peeled for a hardhat laying by the side of the road during my commute to and from work. I will probably end up doing it with strips of Sintra.

Can you explain this in a little more detail? Are you saying you mix super glue and baking soda as a gap filler? Does it sand ok?

Well, I found two conflicting sites. One said that you mix first and have to work fast. Another said to just pour the baking soda on after applying. I went for the pouring on after and it set instantly. Both sites claim that it's sandable. I'd post links, but you have to read a bunch of unrelated stuff to find it. Better to just do a google search.

[albertabeeffett]

Looks like it will be a hit.

[COPENHAGEN6]

I like what you got going there. I think I will definitely attempt my own after I am finished with my current project. Definitely impressed with the cheek areas.

Keep the pics coming.

[joshcube]

Thanks for all the encouragement guys!

Okay, I went to "Play it Again Sports" (used sports equipment store) and all their batting helmets were 50% off. Prices ranged from 7.99 to 29.99, so of course I bought a $7.99 helmet that cost me $4.30 with the discount and tax. It was an adult size (6 1/2 to 7 1/2) and after I tore out the padding and cut the visor and ear guards off it was darn near the perfect size. I only had to cut it in half front to back to make it fit. A few sizes bigger would probably work without any modification.

It glued up nice with good old super glue (also used the baking soda trick to fill a couple gaps) and then I bondo'd the gap in the middle. I didn't have time to shape it, but I will soon.

I know a ton of people have said this, but it's really true that you have no idea how big this helmet is until you see it in person. With the dome on, it's huge! But I know i got the dimensions vaguely right because with just an inch or so of padding, my eyes center up perfectly in the T-visor area.

I took progress pics, but they are still on my camera. I'll probably get them posted in a couple days.

[never_ending_fett]

looking good so far. I like the idea of the superglue and baking soda. can't wait to see more pics.

[joshcube]

The batting helmet:



Glued up:



Bondo'd and sanded:



Side view:



Detail showing how I tapered the bottom:




From the side view pic I was thinking that the T Visor slit is too wide, but the more I look at it, the more I think I need to extend the slit out a little bit more (which will also make it come to a narrower corner). What do you guys think?

[CombatBaby]

definately shaping up!

all these scratchbuild helmets make me want to you guessed it....make another helmet

i commend you

-=QuinN!

[wizardofflight]

That is looking GOOD! Nice job! Keep us updated I want to see how this one turns out.

Alan

[tubachris85x]

I think you may want to extend it ever so slightly, because it appears as if it falls just short of where it needs to be. You should look at some more ref pics, it may give you the answer. By the way, outstanding work!

-tubachris

[goldenrod]

Everytime i see one of these scratch built helmets, it blows me away.
Yeah, do what Tubchris85x suggested and use that ref material to get it just right. I mean your putting yourself into this creation,might as well be picky.
Nice job!

[COPENHAGEN6]

Just checking back in and I see you are definately on track.. You definately have skills... Can't wait to see the next update.

[Huntman]

wow had i this tutorial I would have made my own buy'ce

[joshcube]

Just wanted to let everyone know I didn't drop off the face of the earth. Didn't get squat done on my bucket during the holiday weekend. I'm to the point where I'm ready to add the triangles and the dent, but I'm reluctant to start without knowing exactly where to put them. I tried making ear pieces out of acrylic, because I've worked with laminated sheets of it before and it can be shaped much smoother than sintra. Unfortunately, the individual layers are too hard to cut in the shape I want without breaking. Now I'm debating between grinding down a laminated block of acrylic or just making them out of sintra and coating them with bondo.

Last week I also found that I was unhappy with the flare, so I broke loose several key joints, did some heating with a Creme Brulee torch , inhaled toxic fumes , and reglued it. It was a lot of work with little to show for it, but I'm much happier with it now. I was also unhappy with where the rangefinder "tombstone" meets the helmet, so I filed out the bondo and reshaped that. I also added another coat of bondo to fill in some divots on the cheeks and dome and resanded them. I didn't bother taking pics because I didn't think the difference will show. Hopefully I will get more done on it this weekend.

[mando25]

if you are nervous that the dent might ruin it, make a jango, from kamino since the arena scene has a dented helmet jango.

[joshcube]

Just an update... progress stopped due to the holidays and then I went to the pound with my wife to "just look" at the dogs they had. Now all my free time has been taken up with training my new puppy and keeping her out of trouble.

Hmmm... I wonder what mando dog-armor would look like...

Anyway, the bucket has just been sitting in the office and waiting patiently with it's visor-less stare for me to finish it. I hope to get back to the project this weekend.