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  1. HeadlessHunter's Avatar
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    Jan 24, 2009, 5:55 AM - My ESB Helmet **UPDATE** #1

    This is where the fun begins.......again

    Ok after a short break and a period of swearing blind I would never do another ESB helmet I am having another go and this one will be (hopefully) better than the last, This is following on from my paint up of my old FPH #16! which is now in the posession of our very own Bobby Fett Uk, at the time I was backed into a financial corner so I had to let go of my FPH, not an easy thing to do trust me! But now thanks to a good friend I have got ahold of this helmet casting which I intend to paint up to form the crown of my 12.53% complete ESB suit, here is a pic, the only one I have so far to show where I am, basic trimming done, lots of dust down the back of my shirt etc etc, stay tuned for this as I will be again following the advice of Lee Rogue Studios as far as colours go, with a few little twists here and there, thanks guys and girls
    Attached Thumbnails Attached Thumbnails image020-jpg  
    Last edited by HeadlessHunter; Sep 19, 2009 at 6:54 AM. Reason: update
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  3. Mojo Fett's Avatar
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    Jan 24, 2009, 6:10 AM - Re: My ESB Helmet #2

    Nice start Joe... look forward to the updates!

    That my clone....
  4. HeadlessHunter's Avatar
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    Jan 24, 2009, 6:12 AM - Re: My ESB Helmet #3

    Ha no my friend that is the OSCS helmet I told you about, yours is covered in filler at the moment!
  5. Member Since
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    Jan 24, 2009, 6:16 AM - Re: My ESB Helmet #4

    no they are all mine!!! MINE i tells yer?!?! MIINNNEEEEEE

    *curls up in a slobbery mess*

    lookin fwd to this mate

    Nate
  6. Mojo Fett's Avatar
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    Jan 24, 2009, 6:35 AM - Re: My ESB Helmet #5

    Quote HeadlessHunter said: View Post
    Ha no my friend that is the OSCS helmet I told you about, yours is covered in filler at the moment!
    I know... was only jesting ya!
    go get sanding...
  7. ShocKNurse's Avatar
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    Jan 24, 2009, 7:02 AM - Re: My ESB Helmet #6

    Are you sure that it is FPH #15? If it is, the helmets have learned to spawn themselves...or maybe a little mitosis for all you biology nerds. Thing is, I have a FPH #15 in my possesion at this very moment. Could it be from a different run?? Weird...
  8. 22ssplt's Avatar
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    Jan 24, 2009, 7:47 AM - Re: My ESB Helmet #7

    As soon as I saw #15 I was like huh?

    Quote ShocKNurse said: View Post
    Are you sure that it is FPH #15? If it is, the helmets have learned to spawn themselves...or maybe a little mitosis for all you biology nerds. Thing is, I have a FPH #15 in my possesion at this very moment. Could it be from a different run?? Weird...
  9. HeadlessHunter's Avatar
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    Jan 24, 2009, 7:48 AM - Re: My ESB Helmet #8

    Ha ha oh dear my mistake it was #16!!! apologies!

    Edited original post
  10. formerly old_jedi_mind_trick Bobby Fett UK's Avatar
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    Jan 24, 2009, 7:52 AM - Re: My ESB Helmet #9

    Better than the last

    that will be a tall order indeed and yes it is 16.............just here.............................................. .......................... I
  11. HeadlessHunter's Avatar
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    Jan 24, 2009, 7:54 AM - Re: My ESB Helmet #10

    Thanks Rob, oh and thanks for the number confirmation! Getting sloppy in my old age...
  12. ShocKNurse's Avatar
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    Jan 24, 2009, 9:13 AM - Re: My ESB Helmet #11

    Whew!!! Too bad though, I thought maybe we had a Nobel Prize in order or something...
  13. HeadlessHunter's Avatar
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    Jan 26, 2009, 5:48 AM - Re: My ESB Helmet #12

    More trimming and primer coat #1, going back for a second all over sanding with some finer grit wet and dry to get any imperfections dealt with
    Attached Thumbnails Attached Thumbnails image034-jpg   image035-jpg  
  14. Spideyfett is offline Spideyfett
    Jan 26, 2009, 8:34 AM - Re: My ESB Helmet #13

    This should be good... can't wait to see your work on this one Joe.
  15. HeadlessHunter's Avatar
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    Jan 26, 2009, 6:37 PM - Re: My ESB Helmet #14

    Thanks Alex, I'm excited to be painting another bucket, on the road to improvement hopefully
  16. Darth Nickel's Avatar
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    Jan 26, 2009, 7:55 PM - Re: My ESB Helmet #15

    I'm looking forward to seeing this progress.
  17. HeadlessHunter's Avatar
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    Jan 31, 2009, 11:29 AM - Re: My ESB Helmet #16

    Oh My Lord!! What have I done? All becomes clear, drilled out the cast Borden to fit the real one
    Attached Thumbnails Attached Thumbnails image001_1-jpg   image007-jpg  
  18. Member Since
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    Jan 31, 2009, 2:00 PM - Re: My ESB Helmet #17

    Quote HeadlessHunter said: View Post
    Oh My Lord!! What have I done? All becomes clear, drilled out the cast Borden to fit the real one

    What have you done!?!!?!?!? It should be glued on!!!!




    Nah, I'm kidding, nice work!
  19. HeadlessHunter's Avatar
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    Jan 31, 2009, 2:12 PM - Re: My ESB Helmet #18

    Ha ha nice try
  20. fettpride's Avatar
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    Jan 31, 2009, 3:13 PM - Re: My ESB Helmet #19

    Where'd you get the purdy MR casting !!! I want one

    I'm sure you're going to do her up dandy brother Can't wait to see the progress on this !

    FP
  21. HeadlessHunter's Avatar
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    Jan 31, 2009, 4:08 PM - Re: My ESB Helmet #20

    Chris you got a PM I was hoping to get a little paint down on this helmet over the weekend but another project took all my primer, cheers Gav So I have spent my time going over details like the keyslots again, just to make sure its all ship shape, as well working out a nice method to secure my Borden, I managed to make it removable for painting - method to follow
  22. Mojo Fett's Avatar
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    Jan 31, 2009, 6:19 PM - Re: My ESB Helmet #21

    Quote HeadlessHunter said: View Post
    but another project took all my primer, cheers Gav
    Me? nice work buddy...
  23. HeadlessHunter's Avatar
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    Feb 1, 2009, 7:35 AM - Re: My ESB Helmet #22

    Ok my step by step guide to fitting my Borden Connector, firstly you need to grind away the old cast borden so I whipped out my 'trusty' dremmel and fitted the smallest sanding drum, I then ground away about 75% of it leaving the last25% to be done by hand, I didnt want to risk sanding into the main part of the cheek after its all sanded smooth I took a 7mm drill bit and drilled through, but before you go drilling through your helmet its important to make a 'spot' to guide your drill through, otherwise your drill may slip and either hurt you, or hurt your helmet, what I suggest is getting your drill bit and holding it over the center of the area you wish to go through, then apply some pressure and give it a few light twists, this should creat a small spot face where you can later position your drill, you will also find you are less likely to shatter your helmet unlike if you just drive a drill through with a lot of force Lesson over Anyway the diameter of the real borden is 9.5 mm so I file out the remainder of the hole by hand, I am not making it a size hole as I just want the borden to sit in the hole, not go all the way through, from what I can tell there is about 2.5mm of borden sticking out on the original helmet, the rest is glued through the helmet. Next step I got some 5 minute epoxy and fixed my borden to an M5 bolt, I held it in place with a small g-clamp until the epoxy had cured (see picture) Next up I reprimed my helmet where I had removed the cast borden and made my hole (see picture) The borden, now attached to the bolt now simply drops into the hole and sits in the slight recess, I then used 2 washers and a nut to secure it from the otherside (see picture) the helmet is now ready for paint and I can remove the borden at anytime during the painting process, hope this is of some benefit to you guys

    Big thanks to Gav MojoFett for the real Borden
    Attached Thumbnails Attached Thumbnails bordenclamp-jpg   re-primer-jpg   likeso-jpg  

    secure-jpg   ready-jpg  
  24. Member Since
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    Feb 1, 2009, 7:54 AM - Re: My ESB Helmet #23

    Great tutorial and great helmet, this is going to turn out really nice. Nice clone lid in the background too
  25. Mojo Fett's Avatar
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    Feb 1, 2009, 11:39 AM - Re: My ESB Helmet #24

    Nice... and a great tutorial bruv!
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    Feb 1, 2009, 12:39 PM - Re: My ESB Helmet #25

    Well done!

    Mojo, Email sent