My attempt at a WOF scratchbuilt...

WOW, You people amaze me when I see you guys build scratch built helmets. Very nice work so far bud.:thumbup

Looking good! I can't wait to see more progress on it

Welcome to the fold my friend. You'll find untold satisfaction from making your own bucket, I know I did.

It looks like you're off to a good start, just don't loose your momentum. If you have any questions, I'm sure that one of us scratch-build veterans would be more than willing to share our "trial by error" experience with you. It's always best to learn from others mistakes.

Happy building.

Nice, I am almost ready to buy my signs to do the same as you have. It is amazing on what can be done with regular items. What are you going to use as a top ? Keep pics. coming.

Go Florida MANDOS !!!

Thanks for the encouragement, guys! This is something I've been wanting to do for a while and I'm glad I can share it with you.

Originally Posted by Stinkape fett

Nice, I am almost ready to buy my signs to do the same as you have. It is amazing on what can be done with regular items. What are you going to use as a top ? Keep pics. coming.

Go Florida MANDOS !!!

I got Alan's dome pattern and made a first one out of paper. But, I reprinted it and I'm going to try it with the sign material. This way I'll have something sturdier to put the glass on later.

David.

Very Nice! Looking great so far. Please keep us posted.

I love seeing what folks do with the templates.

Alan

Fantastic!! In the first moment I thought I look at my helmet! I feel honored and understood :-) That's good... Danke Dir auch mein Freund ! (Thank you too friend !)
I am excited to see more

Chris

Keep up the good work, Dave!
Rob

Thanks, Rob. I plan to!

BTW, was it you that posted the idea to use Garage Sale signs? I'm thinking it was but I can't find it in your thread.

I'm planning on starting on the dome this weekend. I'll be attempting two at a time; one with only the sign plastic and one with the foam board. And yes, I will post pics of both.

Wish me luck!

David.

Okay, here's my small dome tutorial.

Using the sign plastic, I laid out the dome patterns...


...and cut them out.


Since I cut every line, I noticed that when the form is bent into shape, the lines break and you end up with over 100 pieces, if you're not careful. So, I put masking tape on the back side of the plastic.


Here's the rear section of the dome after taping...


...and heres the completed dome back.


Here are the front two sections together...


...here's the inside of the completed dome showing my wonderful taping job:o...


...and here's the dome temporarily sitting on top of the bucket.


I noticed that the smaller top pieces of the pattern are harder to tape, so I may either redo the center hub as one piece (out two lines or so), or I may just wait until I do the dome with the foam board.

I'm working on getting all the parts done before I start glassing. I'll post more updates later.

David.

You have alot of patience. Using cardboard and then fiberglass resin, is easier. I personally used the top of a pro-tec skate helmet. But im not going for acuracy. Im doing this whole project as a bet, but have become consumed with it.

DOME TUTORIAL PT 2

A small addition to the dome...

I used the dome base pattern to make a ring similar to the ones made for the main bucket form. Now, it holds its form better.

I don't know what happened, but I think my printer somehow produced a slightly smaller pattern for the dome, or I didn't cut the pattern out right. I had to trim down the outer ring of the base to make it fit inside the dome. Either way, it's a good pattern and a base to put on the glass and Bondo build-up.

David.

KEYHOLE

The outer frame was made with foam board because it was the perfect thickness. The inner parts were cut out of sign material and taped in place.

I used a hair dryer on high-heat to soften the plastic and rolled it on the table with a small bottle.

Here is my result...


David.

Nice, great pictures. How long did it take to this point ?

Off and on, I'd say about two weeks so far. You have to pace yourself. If you go too fast, you end up tired of the project and it starts to become a chore rather than a hobby. Plus, if you go too fast, you start to make stupid mistakes and get really frustrated. I don't ever want to get to that point. That's why, in addition to not having time this week because of overtime at work, I'm taking the week off. I'll get started again probably this weekend with the right ear.

David.

Sorry, guys. I tried to fix a problem with my post and ended up double-posting! Chalk it up to overtime...

David.

Jaiden,
Strted mine as well, your pics were helpful, as well as THD. I have to bake the helm, soon, it's still fighting back a little. I think I have 1/2 mile of tape holding until then. ha ..
Keep pics up. following your lead..

Great job so far!

Yeah...keep it up, Dave!
Rob

Ear build post updated with instructions!

David.

Sweet!
Rob

Nice ears, but they still look a bit on the rough side.

You could easily clean and tidy them up by using some cereal box cardboard to cover over top of the exposed foam. It'll make them look a ton cleaner and it'll protect the foam from melting when it comes time to spray on the primer. ( the propellant in spray cans eats foam. )

Originally Posted by Jango72

Nice ears, but they still look a bit on the rough side.

You could easily clean and tidy them up by using some cereal box cardboard to cover over top of the exposed foam. It'll make them look a ton cleaner and it'll protect the foam from melting when it comes time to spray on the primer. ( the propellant in spray cans eats foam. )

Yeah, I thought about that. I tried a test piece with clear coat spray paint and that's exactly what it did. I actually thought of using more of my sign plastic as a cover. My only concern is that they might "grow" a little.

Unfortunately, I have another marathon work week ahead of me and I won't be able to do much of anything until later in the week...

David.

Sad to hear about your impending work-week-marathon, but we all need to pay the bills.

As for the ears growing, that will happen but only by a half millimeter on each side if you use the cereal box cardboard. ( I don't know how thick a material your plastic signs are. ) The finished look will far out weigh any growing that might incur.

Originally Posted by Jaiden

Yeah, I thought about that. I tried a test piece with clear coat spray paint and that's exactly what it did. I actually thought of using more of my sign plastic as a cover. My only concern is that they might "grow" a little.

Unfortunately, I have another marathon work week ahead of me and I won't be able to do much of anything until later in the week...

David.

Actually, I heard today that the OT was canceled for this week

I could have used the money, but now I have more time for my bucket.

I'm so tired...

I'm trying the sign material covering. Pics are coming!!!

David.

I've been working steadily with putting the sign material on the ears, but decided to stop and possibly redo the left again...This time, I'll just get it ready for glassing. I chalk everything up to experience, and I do like what I came up with, but it's a bit time consuming.

But, I have better news...I finally got the first coat of glassing done on my bucket.

Here's the bucket - preglass...

The kit I used is a standard fiberglass mat/cloth kit from Wal-Mart (around $10). It comes with a 3 square-foot mat that's perfect for one coat if you cut it into four pieces.

Here's the front after glassing...

...the side...

...and the back.


Oh, and I can't forget my little helper. He found an old respirator that I'm keeping for a possible costume addition in the future.


I'm going to give it a couple of days to let my (fume-induced) headache go away before I begin the bondo-fill on the dome...

David.

very interesting to see this come together....looking good

Hey! I think I recognize that green in-progress helmet shape in the background from the RG site. Looking forward to progress pics on your mando lid here.

Now I engage safety mode and ask about the respirator on your helper... please tell me you make sure it fits on properly when he's there with you - or if it can't be made to fit that he's not present when you're using the stuff. ????

OK, now I disengage safety mode and go back to the topic. What do you plan to use to smooth out the f'glass with? I've had good results with 40 grit sandpaper - and elbow grease. Lots of elbow grease.

Originally Posted by Gypsyboy

Hey! I think I recognize that green in-progress helmet shape in the background from the RG site. Looking forward to progress pics on your mando lid here.

Yup...that's my green foam Imp Guard first try. It's about 3/4 the size it needs to be and I've put it on hold for now.

Now I engage safety mode and ask about the respirator on your helper... please tell me you make sure it fits on properly when he's there with you - or if it can't be made to fit that he's not present when you're using the stuff. ????

That thing is so old, I doubt it even meets OSHA standards anymore. I don't even have filters for it. No, my son wasn't nearby when I was working. He has his area in the garage where he plays, but it's not near my workbench. He just thought the mask made him look funny.

OK, now I disengage safety mode and go back to the topic. What do you plan to use to smooth out the f'glass with? I've had good results with 40 grit sandpaper - and elbow grease. Lots of elbow grease.

I'm using the glass as a base for the Bondo work. I have a friend who is going to loan me a small sander to smooth out the first coat once that is ready to sand. It's been a while since I've worked with Bondo, so I'm taking my time.

David.

Ah, so you are putting the glass on there to keep it a rigid base for the bondo applying part?

Yep, and speaking of the Bondo...





I'm hoping to borrow a sander this week so I can make this look more like a true Mando and less like Freddy Krueger's illegitimate love child.

David.

LOL Freddy Fett!!! Nightmare on Tattooine!!

Looks like you got a lot of sanding work ahead of you, but the good news is bondo shapes up really nice.

Actually, the mask does make you son look funny. But then, it'll make anybody look funny. I like to draw goofy smiles and stuff on my dust masks. Big monster mouths with fangs and stuff. Lips so full of colagen they look like they'll pop any moment. That kinda stuff.

Ah yes, pink concrete, better known as bondo. I used about three thin coats just as seam filler on my dome. It took FOREVER to get the high spots down. I thought my arm was gonna fall off, or else I'd end up with forearms like Popeye!

I thought about using my circular sander, but I decided to do it by hand. I started with a wet/dry sanding block, coarse grit, then went to the fine grit one. I ended up doing it in the sink with water running over it some. Cut down on the dust and gave me a smooth finish.

When you get finished, that's going to be one solid bucket! Keep up the good work. I can't wait to see it when it's complete. Good work on the ears, BTW.

I did my sons jet pack the same way and it turned out okay. Foam + fiberglass kit + bondo. It was ALOT of sanding though. (yes, I know its not accurate... lol...) I can't seem to find the pic, but it looked exactly like that helmet of yours. Like a bondo birthday cake.

Hey, for a kid's costume, that jet pack is way better than anything you could buy at walmart. Good job on it.

Question for Jaiden, again.... Where exactly in Walmart did you get the Bondo and the polyester Fiberglass resin stuff? I looked all over the automotive and hardware sections, near the paint, and sheet rock repairing kits................... Nothing. And Walmarts website says they don't carry Bondo at all. I know local stores usually stock extra stuff that is more popular in their region and don't really get supplied by the main company. I looked on Lowes website and they have "all purpose putty". Is that the type of bondo I need to do what you just did?

I'm just so disappointed. I had a list of around ten things to buy tonight including craft rings and bondo, fiber glass and a few spreaders, etc. Didn't have ANY of it. I ended up buying some cool kamikaze riding goggles though. Figured they will be on my head under my helmet!



~Bio

The fiberglass kits might also be with the boating stuff... But... I always find it in automotive. To save time and hassle just hit a place like Advanced-Auto or Pep Boys. They tend to carry both.

Originally Posted by Devilstar2k2

The fiberglass kits might also be with the boating stuff... But... I always find it in automotive. To save time and hassle just hit a place like Advanced-Auto or Pep Boys. They tend to carry both.

Ah, yeah. I spent more time in the Home Fix It departments. Spent about 1/8 of the time in Automotive. Thought it was for home stuff for some reason.

I'll hit either Auto zone or Advanced tomorrow. Both right next to each other, as always. Any idea about the general prices of each? I'm assuming about $10 give or take?

Thanks!

~Bio

Originally Posted by Devilstar2k2

I did my sons jet pack the same way and it turned out okay. Foam + fiberglass kit + bondo. It was ALOT of sanding though. (yes, I know its not accurate... lol...) I can't seem to find the pic, but it looked exactly like that helmet of yours. Like a bondo birthday cake.

you've got to post a tutorial for this! i want to do one up to give as a christmas gift to the little boba i made for halloween

Originally Posted by biohazard388

Ah, yeah. I spent more time in the Home Fix It departments. Spent about 1/8 of the time in Automotive. Thought it was for home stuff for some reason.

I'll hit either Auto zone or Advanced tomorrow. Both right next to each other, as always. Any idea about the general prices of each? I'm assuming about $10 give or take?

Thanks!

~Bio

Bondo is around $7 per can, and the fiberglass kits ( I think) were $20ish. Hope that helps.

Devilstar is half right. The Bondo I bought did cost about $7, but the repair kit was only $10. In my WM, it's in the repair section where all the automotive paints are. No two stores have the same layout, but it's there.

David.

Ah, well that price sounds better to me then. I'll have a look at Walmart first. Probably get a better price there than I will at one of those Auto places. I'll let you know how my scouting goes!

Hmmmm... methinks I recognize that jet pack from a thread on the STT. ???? Yes?

Originally Posted by Devilstar2k2

I did my sons jet pack the same way and it turned out okay. Foam + fiberglass kit + bondo. It was ALOT of sanding though. (yes, I know its not accurate... lol...) I can't seem to find the pic, but it looked exactly like that helmet of yours. Like a bondo birthday cake.

Whats the STT?

Sorry, thought the jet pack was similar to one made by a member of the Sith Training Temple (www.sithtrainingtemple.net). The STT is a Darth Vader scratch-builders' site, but we have a little bit of bounty hunters and stuff there too.

Please excuse my shameless plug. If posting the link above is inappropriate I will be happy to remove it.

It should be fine.

Update: I have only slept two hours since my last post. Been awake about 38 hours now or so. I lost count. Anywas, I'm finishing up a few chores around the house and then I'm off to Walmart to find some of that stuff. Maybe Ill have more luck.

Originally Posted by biohazard388

I have only slept two hours since my last post. Been awake about 38 hours now or so. I lost count. Anywas, I'm finishing up a few chores around the house and then I'm off to Walmart to find some of that stuff. Maybe Ill have more luck.

Dude, get some sleep!

Progress has been made! Even though I wore a mask, I think I'm going to be tasting Bondo dust for a while.





This is still a very rough shape.

I sanded until I broke my first piece of paper. That's why the cheeks still look like a bad frosting job.

There are quite a few places that need filler, places where the fiberglass cloth was thicker than I expected and places where the Bondo was thinner than I thought. I think my wife is getting me a Dremel for my birthday (Nov 13, hint, hint) which will be great for the finer detail.

David.

Oooh. I need more pics! More progress much be made!

Not as much progress as I'd like, but a bit at a time will get 'r done...

I ran out of hardener after this batch, but I got a little bit of patchwork done this morning. I'll be sanding this later today. I'll hopefully be picking up more hardener today also.





David.

More sanding and building up with Bondo...

I'm taking my time now because I really need a mouse sander.

Basically, all I did was make up three small batches and spread them on the face until it was the thickness I wanted.

Here's the left side...

...and here's a close up of the left cheek.


I do have some small places to touch up with small bits of filler, and I'm not too worried about the visor area. I can always trim that down later.

If I have time tomorrow, I'll be working on the right side.

David.

Dave...it's lookin' good!
Are you ready to start huffin' Bondo dust?
Rob

Already there, Bro.

Wait, was that a red Smurf?

Ah, nope, just a Bondo Bunny...

It looks like Red Tide has hit my garage!!!

David.

Originally Posted by Jaiden

It looks like Red Tide has hit my garage!!!

David.

Not even going to touch that one. But on a more serious note, awesome bucket so far, man! I'm scratchbuilding mine out of cardboard presently too... Hope it turns out as good as yours!

Originally Posted by xero

Not even going to touch that one.

Aw, why not? Everything in my garage is covered in Bondo dust. Red Tide is an algae bloom on the coast that's really nasty.

Red Tide in my garage.

Where is your mind?

David.

Brief Update...

I was able to borrow a mouse sander earlier this week and I've been really hitting the face hard with build-up and sanding. I got some $$$ for my birthday and I'm picking up a router today!

Pics are coming!

David.

Awesome, Dave! Post as soon as you can....
Rob

FINALLY!!! Progress pics I can post.

I picked up a Dremel today ($39.99 WM 7.2v with 50 piece kit) and got a LOT of work done. That, and a lot of patience with the mouse sander, I think it's just about ready to paint.




And my favorite pic so far...


There are still a few places that need some patching and the whole thing needs a fine grain sanding, but for now, I'm relatively happy.

David.

That's some great progress.

Now you'll hit the seemingly never ending "fine tuning" stage of the build. I'm still tweeking the dome on mine as I can still feel teeny tiny indents here and there... not that any one other than myself would ever know that they're there.

I got the first coat of primer done this morning.




Next: the fine sanding...

David.

Okay, I've officially reached a stopping point. I am now at 75% complete on this bucket. I'm going to set this aside for a while to work on the ears and the keyhole insert.

Here's the yellow face...

...and the silver cheeks.

A closeup of the left cheek.


And just for comparison, here is my WOF bucket next to my Rubies.


Once again, many thanks and kudos to Alan for his templates.

David.

Dave...don't ya like the bigger bucket better? More room to ring your bell!
Rob

Originally Posted by Ghostsoldier

Dave...don't ya like the bigger bucket better? More room to ring your bell!
Rob

Well, I suppose after the seeing all the purple elephants (from inhaling resin fumes), ringing bells will be a welcome change...

David.

I mounted the left ear. This is the one I covered with the sign material to make it paintable.


Next I'll be working on the right ear getting it ready to paint and install.

David.

I got the right ear finished and installed.

I do have the upper cap done as well, just not in the picture.

Someone asked me if this was going to be the final product.

Once I have all the parts done, I will be casting this bucket to make copies for friends. It will be done with glass and resin. The parts look less than stellar now, but they will be used as molds.

Oh, and just for fun, here's a pic of me and my son in our matching buckets. I used MS Paint to color in the visors and this was before I put the right ear on mine.


David.

I decided to work on the RF pieces today. I forgot to take progress pictures, but I do have the finished (so to speak) pieces ready to cast. If I can't get scrap aluminum for my stalk, I may look into getting one from someone here - if they are still selling them.

What I did was use more of the sign material. Luckily I was able to find scraps big enough for it. I put masking tape on the outside edges and hot-glued the bejesus out of the inside.

Here's the top and bottom pieces separated.


For comparison, here are two views of mine next to the '97 Rubies RF. (The top and bottom of mine are taped together. I did that so I can cast it later.)



And here is my bucket with the pieces all put together temporarily. I cut a stalk out of foam board. It holds up for a while, but is WAY too flimsy.


Questions? Comments?

David.

That looks sharp, Dave! Yeah...that stalk could use some Viagra!
Rob

lookin good dude

Originally Posted by Ghostsoldier

That looks sharp, Dave! Yeah...that stalk could use some Viagra!
Rob

Okay, Rob. I took your advice.

This RF stalk is only temporary because I really want to put lights in it, but I worked on a resin casting yesterday. My permanent one will have a wire conduit and mesh reinforcement.

But for now, this is what I did...

I got some advice on making the resin stalk from someone who messes with fiberglass as a business. He said to use floral foam, so I chopped the dome off my failed IMP guard helm and shaved out a stalk form using my foam one as a template.

Here it is with the foam stalk inside.

I mixed up a one ounce batch of resin and poured it in.

After about three hours of drying (really less, but it's Christmas and I had shopping to do), I pulled the cast. I knew going into it that each time a cast is done it's a one-time shot, but that's okay for one or two pieces.

Here it is after a little cleaning with a Dremel and sander.

I did have to sand down the thickness to make it fit inside the ear...

...but after painting I think it turned out pretty well.

(Not helm related, but) I found a great pair of gloves for my costume. The colors match nicely, don't you think?


David.

The colords do match pretty well. I love Mechanix gloves. :-P I wore a pair of them in Iraq on foot patrols rather than the nomex flight gloves.

And I'm... a mechanic... ? *evil cackle*

Good job on the RF stalk, man. Only thing I'll say about it is that the "foot" isn't supposed to be sunk all the way into the RF.

You're absolutely right. I didn't think about that. I'm going off of Alan's templates and that's the size of it. But, it shouldn't be too hard to modify the pattern when I recast it for wiring.

Thanks for the heads up!

David.

If you're going to recast it for wiring, I would actually suggest two things:
1. Make the foot taller, so you can sink it into the RF if you want to
2. When you make your cast for wiring (and I've been giving this some thought as well, as my RF stalk is made out of plastic signs superglued together, then filled with hotglue) put a very thin coat down first, and let it set a little bit, lay your wires down in there, and then pour the rest of the resin in. Should end up with a very solid resin shaft with wires cast right into it.

A friend of mine at work suggested putting a bendable straw in the shaft and pouring the resin over that. Now that you mention the sign material (I feel :o that I didn't think of that either) I'll probably try it again tonight.

The bendable straw would exit the stalk at the top for the RF and out the side where the "channel" is.

David.

Oh man. Oh MAN. That's a GREAT idea! I'm gonna have to do that too... ****. I can't believe I didn't think about something like that. :-P Just make sure you put down the thin layer of resin first (so the straw isn't visible on the side that it was resting on) and it should turn out great.

Great work! Love the Paint job.

STALK UPDATE!!

My stalk is...leaning!

After about three days, and because I didn't put any kind of support in it, my first attempt at a resin stalk was...almost a success.

The good news is, I learned.

So this time (sorry, no repeat pics) I used a bendable straw for the wire conduit, half resin and half bondo for the main body.

Here is a pic of my stalk evolution...

On the left is my first one. I used foam core board coated with resin. It's stiff, but the resin melted the foam around the edges. In the middle is my second one - the one that leans. You can't really see it in the pic, but I also had a lot of bubbles from not mixing properly. And the one on the right is my latest one. I also added about 1/4 to 1/2 inches of extra material at the top to properly seat the RF.

Here is a close-up of the top with the straw conduit. (Sorry it's fuzzy. My camera hates me today.)


And here's all three stalks again, but the new one has a temporary wire through it to show my success.


COMING SOON!!!
RESIN-CAST EAR BUILD USING FLORAL FOAM!!!

David.

Originally Posted by Jaiden

Because I didn't put any kind of support in it, my first attempt at a resin stalk was...almost a success.

The good news is, I learned.

Thats what's it's all about bro... learning where you went wrong first time and learning from it? press on and keep us posted?

Nice updates...

That third one looks great, man. Good job! I'm gonna pick up some resin and fiber this weekend while I'm out, and give mine a shot.

My final ears are going to be resin cast, but here's my finished stalk installed (temporarily) with my current ears.


David.

That one looks much better, man. When I redo my ears and stalk, I'm going to try and make it stand upright like yours. Much better than the slightly angled in look that I've got right now. I like how you set your inner ear into the helmet, rather than build it outwards. I might try that, but I'm a little skeptical of cutting into my dome. :-P

Sorry for no pictures in this post. I do have some coming.

I've been very busy over the past month with my job and working on my armor pieces, but I never forgot about the crown.

I've reworked my ears with moulds and resin casting. I'm working on attaching the right ear cap right now and need to take a trip to Home Depot for bolts.

I should be able to post pictures later today with my progress.

David.

Picture time!

I've been using resin for my ear caps. The only problem I've found is the added weight. But, it's something I'm willing to put up with.

Here's the left ear.

Compared to the old one...

Attached to the bucket.

Here's the right ear pieces (sans cap).

Here's how I'm attaching the top ear cap. I'm using 1/4 bolts set into the cap. The center hole is for the bolt I used to hold the stalk on.

The stalk attached (repainted black).

Right ear cap on...

And just to show the other nuts that will occupy this lid... ;D


That's it for now. I'm still considering redoing the stalk...again... ( because it is still LEANING!!! :

David.

Okay...finally an update to the never-ending modifications. :P

First of all, I did finish the last step I was going for. Since I was originally going for closer to the standard Jango mando style, I did try for the stalk, as you can see. But, my stalk broke. I tried another one and it still leaned, so I set is aside for a while.

Since I work in construction, I'm always finding interesting tidbits that I might be able to use.

Starting with a duct volume dampener handle. (Basically, it turns a metal flap inside the ductwork to cut down on the air flow. But anyway... :-X)

I wanted to use it for the right ear as kind of an antenna. But I wanted to be even with one on each side. So I started by pulling off the left ear and trimming it out so the antenna could fit flush.




Then I thought, hey. It's my bucket and I'll do what I want to it. So I ripped off the right ear, smoothed out the ear arch on the dome,

filled, sanded, and started painting.




I got the yellow done, but I don't think I like the way the paint came out.

If I can't touch it up better, I may repaint.

Here's the improved left ear (temporarily) in place.



Now on to making the mold and casting the new right ear!

David.

I really love the colors, maybey I will do my helmet in other colors to. Does somebody know a good thread with some examples of custom helmets ?

Thats preety cool man!

wow tanks Jaiden

Originally Posted by Boba Luke

I really love the colors, maybey I will do my helmet in other colors to. Does somebody know a good thread with some examples of custom helmets ?

We have a Dented Variants section here on TDH.

Thanks !