MANDO HELMET FABRICATION CONCEPT

Hi guys,

I've been wanting to make a Fett helmet from scratch for sometime now, but couldn't get my head around how to do it. After thinking long and hard about it, I came up with the following concept. Let me know what you think.

1/30/2013

MANDO HELMET FABRICATION CONCEPT

STEP 1 - THE FORM

The form will be created by first making an MDF framework using the top, side and left/right profiles from the Wizard Of Flight templates, scaled up by approx. 15%, to match the size of the Hasbro helmet. This framework will then be filled in with pink styrofoam insulation, and sculpted to shape. It will then be filled and sealed with drywall joint compound and given generous layers of primer and clearcoat. Separate forms will be made for the dome and the lower half of the helmet.

STEP 2 - FIBERGLASS

The form will then be coated with generous amounts of mold release (Turtle Wax?), and a first layer of resin will be applied, followed by 2 or 3 layers of fiberglass mat. An additional 2 or 3 layers of resin will be applied after that.

STEP 3 - CUTTING

After removal from the form, the helmet pieces will be trimmed and cut, following the same templates used to make the form. Any remaining pieces of the helmet will be fabricated from styrene and MDF.


That's the concept for now. The only material I'm missing is the fiberglass mat. I'll have to look for a place to purchase it inexpensively. I'll be happy to hear everyone's thoughts on the feasibility of this idea. Thanks!

Why not sculpt the helmet, make a mold and cast it?

Although I dont really see the use in making a helmet thats so over produced by many people. Its readily available...I dont see you saving any $$ by doing your own really.

Well, for me, it's not really about the helmet per se, but more about the process of making it. I know it's been done, but it hasn't been done by ME. If the fabrication turns out the way I want it, I may turn it over to someone else for painting. That's a part of the process I've never been very fond of, lol.