My visor cut-out & intallation technique

  1. #1
    Cruzer's Avatar
    Member Since
    Aug 2004
    From
    Porterville, California
    Posts
    2,747

    My visor cut-out & intallation technique

    Hey guys and gals. I had some extra time, so I thought I would take the time to document and share the technique I use to cut out a visor from a welding shield for installation. I'm using one of my CW Deathwatch fiberglass helmets, but it's pretty much the same on any fiberglass helmet. This might be common practice with all of the experience around here, but I thought I'd post something just in case or for the new members.

    Take it easy,
    Cruzer

    First I cut channels on each side of the helmet with this bit. Once the channels are cut, I usually go back over the channels with some 120 grit or so sandpaper to smooth out the channels...
    dsc04513-jpgdsc04514-jpgdsc04515-jpgdsc04517-jpgdsc04518-jpg

    Next, I measure the width I'll need for the visor area on the helmet (I add 1/4" to each side to account for the channel). I apply blue painters tape (cleaner release) to the front of the welding visor, find the center line, trace the cut out visor area on the tape, and start marking for a symetrical visor. I usually leave about a 1/2" lip around the traced shape...
    dsc04519-jpgdsc04521-jpgdsc04524-jpgdsc04525-jpgdsc04526-jpgdsc04530-jpgdsc04531-jpg

    Then I start cutting out the visor with a cut off wheel and the Dremel set at a low RPM speed that almost seems like it will stop if pressed too hard. A higher setting melts the visor material quickly and creates more burrs. I make an initial channel with a first pass and then finish up and cut through with a second pass. I then carefully sand off the burrs with some 120 grit...
    dsc04532-jpgdsc04533-jpgdsc04537-jpg

    Now I have a perfectly fitted visor that is ready for glue-in installation, or I can drill out some holes for a removable visor installation using t-nuts, bolts, and acorn nuts...but that's a different tutorial! Enjoy
    dsc04542-jpgdsc04544-jpg
    Last edited by Cruzer; Jul 6, 2010 at 3:44 PM.

  2. #2
    Mullreel's Avatar
    Member Since
    Jan 2010
    From
    North Texas
    Posts
    1,900

    Re: My visor cut-out & intallation technique

    excellent tutorial.

    This should be stickied

  3. #3

    Re: My visor cut-out & intallation technique

    Thanks for the great tutorial. I'll hopefully have a go at this soon.

  4. #4
    NikNak_aka's Avatar
    Member Since
    Oct 2006
    From
    Los Angeles, CA
    Posts
    532

    Re: My visor cut-out & intallation technique

    Great tutorial. Might get better traffic in the helmet forum. I added it to the wiki under the tutorials section. Tutorials - Star Wars Costume Wiki

  5. #5
    Account Deactivated
    Member Since
    Apr 2008
    Posts
    1,792

    Re: My visor cut-out & intallation technique

    NICE WORK WIS ID SEEN THIS A MONTH AGO B4 I BALLSD MYN UP

  6. #6
    Evilhemmes's Avatar
    Member Since
    Aug 2010
    From
    Ipswich QLD Australia
    Posts
    211

    Re: My visor cut-out & intallation technique

    Mmm nice, Gun thread

  7. #7

    Member Since
    Dec 2010
    From
    Hawaii
    Posts
    60

    Re: My visor cut-out & intallation technique

    VERY HELPFUL! Thanks for this!

  8. #8

    Re: My visor cut-out & intallation technique

    I'm still stuck on seeing "..extra time.." as a phrase in a Cruzer post. Seriously, thanks Cruzer for the awesome write - up!

    Daryl

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