Page 4 of 5 FirstFirst 12345 LastLast
Subscribe
  1. Noob Fett's Avatar
    Member Since
    Nov 2008
    Posts
    27
    Nov 10, 2008, 6:57 AM - Re: New Scratch Helmet #76

    sa-weet! looking good.
  2. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 10, 2008, 8:20 PM - Re: New Scratch Helmet #77

    Quote t_bone9600 said: View Post
    If you are still looking for 2000 grit paper try the automotive section at Wal-mart or an auto parts store. If Wally World doesn't have it a parts store will.
    My local Wally Worls is not blessed with even Bondo! Let alone high grit sandpaper. I will try the auto shops though, had not really thought about them. Thanks!
  3. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 10, 2008, 8:23 PM - Re: New Scratch Helmet #78

    Quote 987654321a said: View Post
    I think everyone has had those spots when working with bondo. Unless after the bondo cured, they painstaikingly sanded with 10,000 grit. haha.
    Alright, hopefully I have some luck finding the high grit sandpaper at an auto parts store. I had thought of using my dremmel and the polishing attachments to see how it comes out, anyone tried that method with success??
  4. I helped at SDCC '08 987654321a's Avatar
    Member Since
    Dec 2007
    Posts
    760
    Nov 10, 2008, 8:57 PM - Re: New Scratch Helmet #79

    You wouldnt have much luck polishing that out unless you spend a century with the dremel on and you might get somewhere. In my opinion, If you can only find 1000 then that is good enough for this. No need for any higher. Honestly, it looks so good that Just 220 grit, 400, 600, and 1000 for wetsanding in between coats of primer.
  5. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 12, 2008, 7:42 PM - Re: New Scratch Helmet #80

    I have begun round one of resanding. I have started with 400 grit paper, I used the wed/dry type and found that when performing the sanding wet, it makes things really smooth! Thanks for all the input guys on the wet sanding or sanding in general. I would recommend to all that you will be more sucessful when taking the time to sand properly! So here are some shots (not really glamorous, but here they are)....Actually, it looks kind of cool in some spots, I may have to revisit this look for a custom job!

    Eric
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	DSC03006-resize.jpg 
Views:	251 
Size:	68.1 KB 
ID:	29110   Click image for larger version. 

Name:	DSC03007-resize.jpg 
Views:	230 
Size:	63.5 KB 
ID:	29111   Click image for larger version. 

Name:	DSC03008resize.jpg 
Views:	243 
Size:	76.2 KB 
ID:	29112  

  6. I helped at SDCC '08 987654321a's Avatar
    Member Since
    Dec 2007
    Posts
    760
    Nov 12, 2008, 7:54 PM - Re: New Scratch Helmet #81

    Just remember this. Sand until you turn blue! You will be done sanding when you pass out.

  7. RBF's Avatar
    Member Since
    Jan 2005
    Posts
    2,173
    Nov 13, 2008, 1:46 AM - Re: New Scratch Helmet #82

    that looks awesome!!keep it up!!!
  8. Puritan's Avatar
    Member Since
    Nov 2008
    Posts
    35
    Nov 13, 2008, 8:07 AM - Re: New Scratch Helmet #83

    Nice progress on the bucket!

    I am making mine out of 5 gallon paint buckets purchased from Lowe's. I was wondering when is best to apply the mask, before or after constructing the cheeks? In these posts, it looks like the cheeks are constructed using the inner layer before the mask is applied, but I have seen other scratch-builds apply the mask first, then cut out the cheek areas and glue in the cheeks.

    Also is it best to construct the dome and bondo it before applying the mask? It seems that is the best way to maintain the lip around the dome.
  9. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 13, 2008, 7:10 PM - Re: New Scratch Helmet #84

    Quote Puritan said: View Post
    Nice progress on the bucket!

    I am making mine out of 5 gallon paint buckets purchased from Lowe's. I was wondering when is best to apply the mask, before or after constructing the cheeks? In these posts, it looks like the cheeks are constructed using the inner layer before the mask is applied, but I have seen other scratch-builds apply the mask first, then cut out the cheek areas and glue in the cheeks.

    Also is it best to construct the dome and bondo it before applying the mask? It seems that is the best way to maintain the lip around the dome.
    I suppose it is really up to preferences. It seemed to me that it made the most sense to have the form of the lid first before cutting anything out. That way, the shape that I wanted to achieve would already be set and I would not have to force things to fit into place. Basically, the proper shape was the most important thing for me, so shape first, then cheeks later.

    You are correct, I connected the dome to the base first and used the bondo before applying the outer "mask" layer. The proper lip aspect of the outer layer was most important to me there.

    Hope that helps!
  10. Puritan's Avatar
    Member Since
    Nov 2008
    Posts
    35
    Nov 14, 2008, 8:00 AM - Re: New Scratch Helmet #85

    Thanks for the tips. Due to the material that I'm using, I imagine I will need to do something similar to what you have done to build up a flat surface on which to attach the ear pieces.

    I've been constructing the dome using the triangle strips rather than the bike helmet method, but it looks like I will have to trim up some of the pieces in the back a bit to get everything to fit. This material is pretty thick, which will make it sturdy, but it is a bit difficult to work with as far as cutting goes. But considering the buckets are only $5, I'm pretty happy with it so far!

    I have started taking pictures of my progress, and I hope to post some pictures soon, but I don't yet have the ability to start a new thread with the new member rules.
  11. i_am_fett's Avatar
    Member Since
    Nov 2008
    Posts
    19
    Nov 17, 2008, 7:25 PM - Re: New Scratch Helmet #86

    Hey guys! I'm new here. You guys really seem like pros at this and I want some advice!
    Below is a link to a photo of my helmet. I am a LOT younger than you guys. (12) So, obviously it's not very good....I also made it in like 10 minutes so....
    Please, give me some advice!

    http://s393.photobucket.com/albums/p...urrent=001.jpg
  12. I helped at SDCC '08 987654321a's Avatar
    Member Since
    Dec 2007
    Posts
    760
    Nov 17, 2008, 7:44 PM - Re: New Scratch Helmet #87

    i_am_fett, why dont you just start a new thread so you dont take over kebh's thread?
  13. i_am_fett's Avatar
    Member Since
    Nov 2008
    Posts
    19
    Nov 18, 2008, 2:29 PM - Re: New Scratch Helmet #88

    Can do. My bad....
  14. Noturno's Avatar
    Member Since
    Nov 2008
    Posts
    30
    Nov 18, 2008, 6:11 PM - Re: New Scratch Helmet #89

    Wow man, Nice work
  15. SinisterFett's Avatar
    Member Since
    Nov 2007
    Posts
    313
    Nov 18, 2008, 6:31 PM - Re: New Scratch Helmet #90

    That's looking tight. You should get a nice clean cast from that build up. Very nice work
  16. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 18, 2008, 7:55 PM - Re: New Scratch Helmet #91

    Okay gang, I have done another round of sanding, this time in the bath tub with running water and wet/dry sandpaper. It has come out really smooth and very nice. Except one issue keeps coming back to "haunt" me. The holes from the helmet on the top (from the bike helmet); I refilled them with bondo and let them set and dry for about 72 hours. When I wet sanded them, the bondo came off and I still have visible indents where the holes once were. So now here is my question/thought: Should I sand down with a heavy grit and risk doing damage to the area or should I try another round of Bondo and sanding. Has anyone else experienced this? Any thoughts???

    Thanks,
    E
  17. I helped at SDCC '08 987654321a's Avatar
    Member Since
    Dec 2007
    Posts
    760
    Nov 18, 2008, 8:01 PM - Re: New Scratch Helmet #92

    Any pictures?

    Are the filled areas just popping off leaving the original helmet holes? If so, I noticed you are using duct tape. Bondo does not stick too well to duct tape. You could have just used pieces of sign material, like less than 1 mm thick, and glued it on, and filled it.
  18. Strife's Avatar
    Member Since
    Oct 2008
    Posts
    101
    Nov 18, 2008, 9:00 PM - Re: New Scratch Helmet #93

    I'd agree with the above poster. Use something else as a backing, even if it is just some sort of cardstock/cardboard. Duct tape doesnt seem to work too well in this situation...hope the damage isnt too bad. =(
  19. Dead Eye's Avatar
    Member Since
    Jun 2008
    Posts
    77
    Nov 19, 2008, 3:50 PM - Re: New Scratch Helmet #94

    impressive. nice work so far can't wait to see the finished bucket!
  20. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 19, 2008, 6:26 PM - Re: New Scratch Helmet #95

    Quote 987654321a said: View Post
    Any pictures?

    Are the filled areas just popping off leaving the original helmet holes? If so, I noticed you are using duct tape. Bondo does not stick too well to duct tape. You could have just used pieces of sign material, like less than 1 mm thick, and glued it on, and filled it.
    Actually, the pieces are not popping out, the design of the holes from the inside should prevent movement of the filled in pieces. The issue is that the area when sanded seems to have "sunken" below the original level of the outer shell. When I first applied primer, you could se the outline of the original holes. I added Bondo to those areas and have sanded down again. The issue now is the Bondo has actually "washed" away while doing wet sanding so that there is nothing, or well barely anything, left on top of what was already there. I just want a smooth even shape so that you cannot se the original spots when I apply the primer again. Below is the photo that shows them..... Let me know! I added two photos, one before priming and one after. The one after the priming, it is a little tough to spot them, but in person they are pretty obvious.

    E
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	DSC03003.JPG 
Views:	191 
Size:	541.9 KB 
ID:	29256   Click image for larger version. 

Name:	DSC02995.JPG 
Views:	158 
Size:	589.4 KB 
ID:	29257  
  21. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 19, 2008, 6:31 PM - Re: New Scratch Helmet #96

    Quote 987654321a said: View Post
    Any pictures?

    Are the filled areas just popping off leaving the original helmet holes? If so, I noticed you are using duct tape. Bondo does not stick too well to duct tape. You could have just used pieces of sign material, like less than 1 mm thick, and glued it on, and filled it.
    Sorry, forgot to pinpoint the location for you. If you click on the primered photo and can expand it, you can se the outline of the hole in the center of the strip of light going across the top of the helmet.
  22. I helped at SDCC '08 987654321a's Avatar
    Member Since
    Dec 2007
    Posts
    760
    Nov 19, 2008, 6:44 PM - Re: New Scratch Helmet #97

    Oh I see what you are talking about. Well, for that I would say fill it with that red paste, that you can buy at walmart, I forgot what its called, but it air drys and is perfect for this situation. And it is easy to sand. If that doesnt work, then clean your helmet with water and re apply bondo

    Edit- Sorry, I meant, clean your helmet first with water and the apply bondo. Then if that doesnt work buy that filler paste.
    Last edited by 987654321a; Nov 19, 2008 at 6:51 PM.
  23. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    127
    Nov 26, 2008, 9:36 PM - Re: New Scratch Helmet #98

    Okay gang, Boba is back! I feel I have done the best that I can with him after our mishap last weekend. By the way, if you do not know what I am referring to, take a look at my thread titled, "Tradgedy has struck....!" for what had happened. Since the "tumble", I have done a layer of fiberglass. A couple of notes on it, it can get really sticky. If you get some on the outside of the lid, do not panic, you will just need to do a great job of sanding when it is all dry. Also, the strands come off very easily when you apply the resin. Not sure if I was supposed to remove the lose ones as I went, but it added to the mess. There is a mesh type that almost looks like a loosly woven mat of sorts. I wonder if that is any easier to work with? Make sure you add the correct amount of hardener to the mix. I think on the first application I did not add enough and as a result, it did not dry right away and is still a little sticky. On the second coat I made sure I added enough and that seemed to do the trick.
    In any event, he seems really solid now, not that I am going to drop him any time soon! But, if there are any other mishaps, I should be good. Now, I also added another bit of Bondo. I cannot get those darn spots from the bike helmet to completely go away. I am trying more bondo again and a different primer spray to see if it will help. Plus, I wanted to add a little more where the cracks were. So, hope everyone enjoys and has a great Thanksgiving, and to our global brothers, find a pub and give thanks for Boba?!
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	DSC03032a.jpg 
Views:	194 
Size:	85.0 KB 
ID:	29408   Click image for larger version. 

Name:	DSC03033a.jpg 
Views:	165 
Size:	77.9 KB 
ID:	29409   Click image for larger version. 

Name:	DSC03034a.jpg 
Views:	162 
Size:	71.6 KB 
ID:	29410  

    Click image for larger version. 

Name:	DSC03035a.jpg 
Views:	167 
Size:	70.2 KB 
ID:	29411   Click image for larger version. 

Name:	DSC03036a.jpg 
Views:	195 
Size:	77.8 KB 
ID:	29412  
  24. madmanmoe64's Avatar
    Member Since
    May 2008
    Posts
    71
    Nov 27, 2008, 8:46 AM - Re: New Scratch Helmet #99

    Just a thought. The problem with the bike helmet holes arises because the filler material (bondo or red paste) is less tough than the original plastic. So when you sand the area the filler sands down faster than the bike helmet and you get the dips.

    You need to find a filler that is of a similar toughness to the bike helmet. No idea what sort of filler that might be.
    I had a similar problem because I used two different types of polyfiller on my bucket.
  25. Nov 29, 2008, 2:55 AM - Re: New Scratch Helmet #100

    Really inccredible build! Makes me want to crack out a sintra build. I definately look forward to the completion!

Similar Threads

  1. Scratch Build Helmet
    By Jango 425 in forum Expanded Universe Bounty Hunters
    Replies: 15
    Last Post: Jan 6, 2010, 10:58 AM
  2. Helmet from scratch..
    By HuntressTane in forum Expanded Universe Bounty Hunters
    Replies: 3
    Last Post: Aug 1, 2006, 10:15 AM
  3. Scratch built helmet
    By BestBountyHunter???? in forum Boba Fett Helmet
    Replies: 7
    Last Post: Jan 26, 2006, 8:47 PM
  4. Helmet From Scratch
    By Son of Knight in forum Prop Building Workshop
    Replies: 2
    Last Post: Jul 17, 2005, 7:49 PM
  5. Beginning a helmet from scratch
    By AoErat in forum Boba Fett Helmet
    Replies: 31
    Last Post: Jan 6, 2003, 10:07 PM