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  1. le1120's Avatar
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    Aug 22, 2015, 9:27 PM - Le1120's Second Cardboard Helmet Scratch Build -- WIP #1

    After finishing my first scratch built Fett helmet, I had the itch to redo it with all the itty-gritty details that I now knew belonged to it. (These screen-accurate things are never simple endeavors are they?)
    Anyhow, I have started this new project.

    I will allow the pictures to tell the rest (currently)
    (pic heavy!)


    Inside support:



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    And proceeded to dress it up:

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    I cut out the area for the cheeks:

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    I decided to use some 1mm sintra for the outside because it sands unlike cardboard...but we'll see how that goes

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    Advice and criticism is very much appreciated.
    Last edited by le1120; Oct 28, 2015 at 6:42 AM.
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  3. RafalFett's Avatar
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    Aug 23, 2015, 3:23 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #2

    The first major issue in your build is that you used corrugated cardboard to do the inner parts. The second issue is with the outer layer which is aligned with the inner layer at the top and not at the bottom. If you align it to the bottom of the inner layer, the outer layer will have a 5mm recess which will allow the dome slices to sit comfortably between the outer layer and the dome support pieces.

    Other than the issues noticed above, the build looks pretty good so far.
  4. le1120's Avatar
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    Aug 23, 2015, 8:25 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #3

    Ok, thanks. However, what problems will the corrugated cardboard bring me? I thought it would be ok to use on the areas that will remain unfinished...

    I will have to (at this point) simply try to keep the dome parts aligned...I will have some updates on that by tonight (I hope).
  5. RafalFett's Avatar
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    Aug 23, 2015, 9:26 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #4

    The corrugated cardboard is too unstable to use it on builds that needs stiff parts. In this case the pieces you used might warp under pressure of pulling or stretching the layers, which might result in defectuous shapes. This is why I say that this type of cardboard is not the best for these builds, even if you will discard most of these pieces.
  6. le1120's Avatar
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    Aug 23, 2015, 9:55 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #5

    I will keep in mind what you say about the corrugated cardboard.

    Anyway, I began the cheeks:

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  7. le1120's Avatar
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    Aug 23, 2015, 1:23 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #6

    Lol, I accidentally started two threads instead of one like I intended. Here's its link Le1120's Second Cardboard Helmet Scratch Build -- WIP

    However this one here is the one thats going to be updated so I'll see if I can delete the other (if I figure out how).
    Last edited by le1120; Oct 28, 2015 at 6:43 AM.
  8. ToEleven's Avatar
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    Aug 24, 2015, 9:55 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #7

    Oops...yeah I posted in the wrong one. Looking good though. Keep it up!
  9. Demmoc's Avatar
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    Aug 24, 2015, 10:56 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #8

    Looks good so far! I just started my first helmet build middle of last week. Hope all goes smooth!
    At least you remember to take pics. I'm terrible about that.
  10. le1120's Avatar
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    Aug 24, 2015, 8:15 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #9

    Thanks to ya both!

    Progress: I got one cheek on!
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    Yay. I always remember the cheeks being the hardest part to put on from my first scratch build.

    Comments and critiques are always welcome.

    - - - Updated - - -

    Second cheek begun!

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  11. le1120's Avatar
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    Aug 24, 2015, 8:28 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #10

    Well, the right side did not go half as smoothly as the left. I ended up yanking it out because I had to squeeze the cheek parts into the helmet so much that the cardboard piece got really twisted and messed up. This is after I yanked it out (I forgot to take pictures of when it was in).
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    The issue is that although the cheek part can fit in the helmet, there isn't room for the upper cheek piece unless its just totally flat and mashed in there.

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    The other thing is that the mandible of that side bends outward when I keep it in the correct position:

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    What it wants to do is this:
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    which allows more room for the upper cheek....
    but then the space for the visor is a bit pinched.

    Anyway, looking for some help and advice.


    (Rafalfett SAVE ME )
  12. RafalFett's Avatar
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    Aug 25, 2015, 12:53 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #11

    Try to glue the upper cheek first, then squeeze in the lower cheek. As I already said, the corrugated cardboard is not the best choice, especially for the inner parts, as it tends to warp:

    Click image for larger version. 

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  13. le1120's Avatar
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    Aug 26, 2015, 8:35 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #12

    Ok so I don't have any pictures to show, but I started checking the helmet's frame for warps and began work on the frame for the dome using non-corrugated cardboard. I started up my 3D printer, and began printing just the dent from Raf's 1:1 helmet file. I also picked up some XTC-3D which will allow the finished 3D print to look like a finished part. Can't wait for the print to be finished. More updates tomorrow.
  14. le1120's Avatar
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    Aug 27, 2015, 8:52 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #13

    Printed some stuff for the helmet!

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  15. le1120's Avatar
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    Aug 27, 2015, 9:09 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #14

    Well, the cheek piece just doesn't want to fit, so I decided to take apart the helmet and redo the inner support frame with non-corrugated cardboard. (gasp!)
    So, tearing apart the helmet

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    Then rebuilding the frame.

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    Advice and criticism is much appreciated!
  16. le1120's Avatar
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    Aug 28, 2015, 9:29 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #15

    Getting the helmet rebuilt...I think it's appearance is improved but any thoughts?
    I'm still gonna put on the sintra outer layer though so we'll see how things go.

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    Any advice or criticism is very much appreciated!
  17. RafalFett's Avatar
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    Aug 29, 2015, 12:36 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #16

    There's definitely an improvement on your rebuild! Keep up the great work!
  18. ToEleven's Avatar
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    Aug 29, 2015, 10:48 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #17

    Keep it up buddy. All I can say is I find scratch building to be equally rewarding as it is frustrating.

    The new build is shaping up nicely!
  19. le1120's Avatar
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    Aug 29, 2015, 3:26 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #18

    Looking awfully like Split face...

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  20. le1120's Avatar
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    Aug 29, 2015, 5:39 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #19

    Quote RafalFett said: View Post
    There's definitely an improvement on your rebuild! Keep up the great work!
    Thanks a lot!
    Quote ToEleven said: View Post
    Keep it up buddy. All I can say is I find scratch building to be equally rewarding as it is frustrating.

    The new build is shaping up nicely!
    I know, it was the same with my first scratch build...but now I have an even higher standard in my mind that I am reaching for and that makes things harder Thanks.
  21. JedIinTraining's Avatar
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    Aug 30, 2015, 7:50 AM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #20

    Nice!


    Sent from a galaxy far far away
  22. le1120's Avatar
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    Aug 30, 2015, 9:02 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #21

    Well, I finally got the basic helmet finished! The dome is not perfect, and so I will got the usual route of covering it in a nice layer of bondo, which I will also use sparingly on the rest of the helmet. Anyway, pic heavy...

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    Here I did a test fit of the ear pieces which I 3D printed (haven't printed them all yet tho). As usual, advice and criticism is very much appreciated.

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  23. le1120's Avatar
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    Sep 1, 2015, 8:39 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #22

    I wasn't satisfied with the right cheek (the borden side) and so I redid it. I also printed the final ear piece!

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    The funny thing is that the filament I have for my 3D printer is glow-in-the-dark (it just happened to be on sale) and so whenever I turn off the lights the helmet's ears glow. It's really funny to see it in person. Unfortunately the camera doesn't capture it so well.

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    Once again, I really appreciate your advice and criticism. It really helps me see the problems and errors that I was oblivious to before.
  24. le1120's Avatar
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    Sep 4, 2015, 8:24 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #23

    I put some sealant on the cardboard. I dunno if you can tell anything was put on in the photos, but I thought I might as well post them. Sorry for the poor visibility

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  25. le1120's Avatar
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    Sep 6, 2015, 8:41 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #24

    After putting on a second coat of sealant, I put on some bondo glass for filling in the large inconsistencies on the dome and strength. Here's some pics:

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  26. le1120's Avatar
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    Sep 7, 2015, 2:20 PM - Re: Le1120's Second Cardboard Helmet Scratch Build -- WIP #25

    Did some touch up and but in the rear key slot thingy. Next up: pink bondo!

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