I started making my cardboard bucket today. I was able to bend the cardboard by wetting it just a little and then taping it into place.
Discussion on Low budget Boba within the Boba Fett Helmet forum, part of the Star Wars Original Trilogy Bounty Hunters category; I started making my cardboard bucket today. I was able
I started making my cardboard bucket today. I was able to bend the cardboard by wetting it just a little and then taping it into place.
Wha? I wasnt expected that. It looks great.
Thanks guys! I'm starting the top of it now- I'll have more pics later on. Once I get everything filled in I'll coat it with spackling paste and sand it and then coat it with a clear acrylic before painting.
The goal of this project is complete a decent (as in presentable but hardly accurate) Fett costume by Halloween and not spend any money doing it!
I looked around in my garage and I had some left over sintra sheet from building my MIB blasters, some brown vinyl, a flight suit (unfortunately tan) and a fair amount of cardboard and foam. So I figured what the heck, why not? I enjoy a challenge.....
I'll be posting on a regular basis as this progresses.
I love it, it's cardboard! What a wonderful mind you have...talent, too.
Filling in the top...
That is so freakin sweet! I can just imagine someone asking, "Whoa, where'd you get that helmet?" and you replying "I made it out of cardboard."
Nice work. I wasn't not expecting to see that much craftsmenship when I read cardboard.
that looks awsome I wish I had that kind of talent and once you put that puddy on it and sand it down it should be pretty solid.
Now that is different, I never thought of using cardboard. Looks awesome
Thanks for the kind words! I should be able to finish the dome and get started on the ears today. I can only work on it when my son is taking a nap or after he's gone to bed. It's coming together really fast- I'd bet a helmet could be completed in less than a day if you weren't interrupted. The cardboard I'm using is kind of like a thick posterboard- about 1/16 inch thick. The helmet is suprisingly stiff and strong- that's cellulose fiber for you!
The goal of this whole project is to show that it should be possible for anyone to make a Fett costume with a minimum of tools and materials (and not be financially devastated if it gets damaged by some drunk idiot on Halloween.)
and it should be relatively light, too! (Right?)
your helmet is looking pretty darn good so far. great idea, good luck in finishing it. can't wait to see more pics.
Holy hole in a donut, batman.
that bucket is progressing amazingly :thumbup :thumbup :thumbup :thumbup :thumbup
It's looking spectacular so far! I think I can honestly say, "Best cardboard helmet ever!"
Wow, That is really nice! Do you know any place in PA where I could get what you're making it out of?
Dude, it's cardboard. Just make a helmet out of your favorite cereal boxes.
I finished filling in the dome and I cut the visor opening today. I still need to put the slots in the back and make the ears- those will be a challenge to do in cardboard but I'm hoping I can pull it off. I haven't decided what to do about the rangefinder stalk- I might try sandwiching cardboard around some music wire to strengthen it. We'll see....
Oh yeah- it fits perfect! It's amazing how big it is (and it's a good thing as I have a big melon.)
Wow... I'm impressed... I did one of these last year made out of a Pepsi box. It didn't look nearly as good as yours though. I called mine Junko Fett.
that is AMAZING...I will be watching this thread!!
Holy Shnikies is all I have to say. AWESOME dude. Keep us posted!!
That's great man, Hey you gonna actually use a vizor or just use some seran wrap colored with magic marker?
Wow!!! Amazing bucket!!! I love it!
Made the keyslots tonight. I still have to glue it in and then get started on the ears.......
I took a couple of days off the helmet to get started on my armor and jet pack.
Now THIS is a cool bucket thread!
I started smoothing everything with the spackling- so far so good. I still need to add some details and of course the dent.
I can't believe what you have done with this! Great work so far!!!
And here we've been going around buying fiberglass helmets...
How are you going to make the dent?
So, are you gonna harden it somehow? Reinforce it with some sort of thin layer of plastic? It looks way too good to go to waste trooping in once and having to throw away because of sweat-enduced mold.
I'll carve the dent out- you'll see. The helmet will get coated with an acrylic sealer before it's painted. I'm almost there- I've got to finish the ears and make the rangefinder. Been busy working on the jet pack.....
Slowly but surely I'm getting there! Just need to make the rangefinder. So far everything you see is cardboard.....
I can't believe what you have been able to do with this! How many hours do you have into it so far? Congrats on the amazing work.
I guess this only proves you dont need money to have and or make a decent buckt. No more "I dont have money" excuse, however, I'll still use it anyways cause I can.
oh my... and we waste money on fiberglass helmet?! I've got a Pepsi box out in the garage!
I don't know too much about making moulds, but would that survive if you tried to make one?
*** ... I never thought it was even possible to make a good looking helmet out of cardboard. I had no idea how one could get it as smooth as you've gotten it ... in fact I didn't even know if it was possible! Dude, that is some amazing work you've done right there! Keep it up!:thumbup:thumbup
great looking helmet, i agree with JB. wasnt sure how it was gonna turn out, but wow!! cant wait to see it all painted up
If the bucket looks this good, I can only imagine how awesome the rest of the suit is going to turn out. **** nice work!
One last one before I go to bed! Still need to make the visor.......Thanks for all the kind words. I probably have about 12-15 hours in this so far. It is suprisingly rigid! It wouldn't survive making a mold- that much I do know. I think it's going to be a good costume helmet but it'll never be a great replica helmet. All things considered, if the rest of my costume turns out as good as this has I'll be a pretty happy man. I haven't even started on the gauntlets though and Halloween is looming ever closer......
Halloween? I think that will turn out to be 501st quality bucket.
How about you make out out of 1/16" styrene just like you did the rocket, and make a mould? Your crafting skills are too good to go to waste!!
There are also a lot of people that already offer molded buckets. The whole goal of this was to show that it's possible to make a Boba costume with a small budget.
Having said that, there are a few things I'd like to make multiples of- like a CNC machined hollow aluminum rocket. It's possible to do but it would cost a pretty penny....
hey Honus! I've never made a bucket before nor bought one and decided that, after confronting my budget, your cardboard bucket must be the way to go this halloween... so i started my own project =P
i've used only left over pizza boxes and tape that had been scattered about my room... and, so far, it doesn't look so bad...
my question for you is how did you calculate and design the template for the triangles that make up your dome? (sorry, geometry was never my forte)
and, what are you going to do about the visor? (i'm just a poor college student with only 23 cents to spend =P)
Last edited by Germ; 10-17-2006 at 09:43 AM.
*** that is awesome! What next, blaster out of popsicle sticks and bailing twine?
looks awesome! one suggestion... don't make the visor out of cardboard. WAY too hard to see out of
Did you generate lower portion off a template I don't know about - or create that freestlye?
However you did it --- it looks PHENOMINAL!
Thanks for the kind words everyone! The templates I used were the ones posted by Alan here:
Alan is THE MAN! I never would have been able to do this without all his hard work.
I didn't make any exact templates for the dome- I just kind of winged it. I put up a kind of abbreviated tutorial here:
I'm making the visor out of some flexible clear plastic. I'm going to try and see if I can scrounge some window tint for it.
wow! thatīs is the most inventive thing I have see in time....this, and the thrash can armour are the living proof that a BOBA can be made in a lot of artistic ways................YOU RULE, MAN!!
I have a litle surprise too...when I have finish, this forum will we in shock!!!
Nice work. Shows what a little work can do!
Once you seal it up, I think it would stand up to being RTV molded.
Very impressive work!
I think you're well on your way to proving that.
Thanks for the compliment. You have done an outstanding job, I just provided the tools, great work.
I created a set of dome templates similar to yours but I did have the patients to assemble them as well as you have. Give me a couple of days and I'll clean them up and post them for everyone in a PDF file.
After an attempt of two at winging the dome construction like you said in your tutorial i decided to use a littl of my math skills to figure out the precise measurment for the triangles...
basically, since I wanted 10 triangles per quadrant, I had to solve for the perimeter of the base, calculate each arc, then the vector points for each angle of the ellipse... After which I then had to repeat the process vertically... something i had never learned in any trig class.. =(
after a few checks and rechecks i found that it worked phenomenonally! Each triangle matched up to form a perfect dome... I made the template in AutoCad LT and printed them off by quadrant. Unfortunately I cannot figure how to make the template into a .pdf file...
Thanks sooo much Honus! Cardboard helmets are perfect for any individual that wants to make a cheap, fast, and easy bucket for almost any occasion. With help from your tutorial i was able to build my bucket in a matter of 2 days (not painted of course =P).
You used 10 triangles per quadrant???? I haven't tried this method, but I've gotta believe the vertex angle per triangle must be really small. You probably have the exact number, but how were you able to cut the material as precise as it seems this measurement would call for?
Did you lay out the boundaries of each quadrant like Honus did in post #8? If so, then wouldn't you need to use right triangles for the area right next to the quadrant boundaries? It seems if you don't you'll have a gap there. I'd like to see how your helmet turned out.
math is hard.
I would like to see where the quads join...I agree w/ jimmy buffet right angles seem most logical
ok, i'm a little annoyed because was logged out while typing this post
and lost about a page and half of work so here i go with a more condensed
...a nice short explanation =)
(right now i'm home for fall break and all the work I did to solve these
problems are quickly scribbled on many sheets of printing paper at my
dorm so, in turn, every thing posted here is from memory and may or may
not be completely accurate)
Things to know before I get into this are: I used wizardofflight's
templates, the base of the the dome is an ellipse with a major axis of 9
inches and a minor axis of 8.5 inches, the max height is something around
3.75 and the template for the dome height is not exactly an ellipse.
To find the small variation in distance that is caused by the shape of
the dome height template I first had to recognize that the template is,
in fact, made up of two ellipses connected tangently. To solve for how
much this effected the final distance of each triangle. This means, that
I had to solve for the total circumfrence of each ellipse.
The calculations i used to solve this involved finding at what point did
the tangent line connect. To solve this I used:
s = sqrt[4h2+c2/4]+[c2/(8h)]
where h = height, c = chord length, and s = length...
Next, was the more complicated part... I had figure the length of each
vector that comprised each individual triangle unit. (This would have
been made easy had the dome base been a circle... because then every
vector would be just the radius rather than some horribly confusing
variable) To solve this part I used what I was given to create a formula
that would work for all the quadrants (At this point I'm looking at a
sketched out version of the dome base on some graph paper)...
I know that every triangle (since I want ten) will differ by only 9 degrees.
I know that the ellipse is made up of two axis whose radii are 4.5 and 4.25
With this in mind I created this:
(understand i went about finding this using only general quadratic and
parametric equations and that a = axis along the y, b = axis along the x,
and x and y are what they are normally in refrence to graphing, im going
to say that v = theata or your given angle)
tan^-1(b*tan(v)/a) = l // remaining variable (y = tan(v)*x)
then the point common to the ellipse is found by:
a*sin(v) = x // this only works for quad 1 due to 0 < v < 2pi
b*cos(v) = y
(I inputed this forumla into my TI-83 as a prog and ran it for every
angle in the quadrant I and then (cheated) mirrored it.)
Now, the dome base is done...
... im tired of typing for now (sorry) ... but i promise i'll post how i
found the remaining arc length of the dome and how that was implimented
into the overall production of the triangles..
below is a screenshot of the 6-triangle version of the product: (in AutoCad):
Well folks I have updated the helmet template thread to include the flat pattern for the dome. Here is the link;
The dome is not a true ellispe as stated above. So I created a 3D mesh of the dome and then flattened it out. It is divided in to 3 pages with a total of 20 panels. Have fun!!
So basically you need arc length as a function of φ where φ increments by 9° (quadrant 1 would be for 0° to 90°, 2 would be 90° to 180°, etc.) and φ is the angle on the XY-plane. It seems you have vector magnitude as a function of θ. By using the law of cosines, you can find arc length. You can either write a short computer program for summing or use a calculator to integrate (I personally would go with the computer program.
Anyway, very impressive work! I'm interested to see your approach for finding arc length.
wow, simply amazing. i might just have to try this myself and see if i can get it done in time for the 31st. Thanks for the inspiration.
when you start on the gauntlets let us know!
yeah do a tutorial honus some of cant afford gauntlets
Just a thought, but could the templates be printed out on heavy cardstock and then just cut it out and use those pieces for the actual build up? Been trying to think it through a little bit before I start. That would seem the easiest thing to do by saving a step.
Here's an update! Still needs a lot more painting and I have to fix the tint on the visor. It's getting there.....
Simply amazing. Considering the materials, what more can be said?
I think you have a future as a professional prop maker.
Honus you are insane
GREAT LOOKING BUCKET!
Thats one good looking helmet for sure!
Great work there.
Not yet- I haven't worked on it since Halloween. I've been really busy at home and at work. I still have to finish the rangefinder and then do some more painting. The helmet is totally wearable and I wore it to work on Halloween with the rest of my Fett costume- no problems whatsoever.
I've already started thinking about next year's costume! It's going to make building a cardboard Fett look like a walk in the park.....
You did great work, especially on the shape.
What I'm actually looking at doing is a Stargate Horus costume- animatronic moving head and all. Ideally a working staff weapon too.... I've got most everything figured out and I already have the servos.
I also drew up some plans for a cardboard Rocketeer.
Too many costumes, so little time!
Last edited by Honus; 11-10-2006 at 08:24 PM.
does it have a movable rangefinder?
No moveable rangefinder but it could be done.
Holy Wampa's that unbelievable.
I'm working on making my rangefinder movable with the possibility of adding a servo later. I haven't attached the ears yet, but from what i've got so far it seems like it should work well.
That is impressive to say the least. What kind of paint did you use on the cardboard? Did the Bondo stick to the cardboard OK?
that is an amazing bucket, brother! nice work! wish i had those skills....
Absolutly amazing. Great workman ship with the materials.
I wouldnt have ever expected cardboard to work that well.
I probably would have attempted balsaboard.