My visor cut-out &  intallation techniqueSubscribe
  1. Cruzer's Avatar
    Member Since
    Aug 2004
    Jul 6, 2010, 3:15 PM - My visor cut-out & intallation technique #1

    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,

    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...

    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...

    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...

    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
    Last edited by Cruzer; Jul 6, 2010 at 4:44 PM.
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  3. Mullreel's Avatar
    Member Since
    Jan 2010
    Jul 6, 2010, 4:19 PM - Re: My visor cut-out & intallation technique #2

    excellent tutorial.

    This should be stickied
  4. webba fett's Avatar
    Member Since
    Jul 2009
    Sep 8, 2010, 6:32 PM - Re: My visor cut-out & intallation technique #3

    Thanks for the great tutorial. I'll hopefully have a go at this soon.
  5. NikNak aka's Avatar
    Member Since
    Oct 2006
    Nov 15, 2010, 3:56 PM - Re: My visor cut-out & intallation technique #4

    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
  6. BGHunter is offline BGHunter
    Dec 9, 2010, 6:19 AM - Re: My visor cut-out & intallation technique #5

  7. Evilhemmes's Avatar
    Member Since
    Aug 2010
    Dec 9, 2010, 6:43 AM - Re: My visor cut-out & intallation technique #6

    Mmm nice, Gun thread
  8. Member Since
    Dec 2010
    Dec 11, 2010, 5:18 AM - Re: My visor cut-out & intallation technique #7

    VERY HELPFUL! Thanks for this!
  9. zihyer's Avatar
    Member Since
    Aug 2012
    Nov 26, 2012, 4:56 PM - Re: My visor cut-out & intallation technique #8

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


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