FNG here from sunny Florida! I've been lurking around here a while, like what I saw, and decided to join last week. You guys have a really nice forum here!
As a father-sons project (a 16 year old and a 13 year old), my boys and I have decided to do a little SW costuming, and as you can guess, Fett is the subject that came up! So, here I am, finding myself building not 1, but 3 helmets simultaneously! Anyway, I've downloaded Alan's superb templates, and studied Honus, SD68, and slew of others' tutorials on the forum, and as of last night we cut out all the template pieces. We also made a trip to Walmart/Home Depot/Lowes last Saturday, and secured batting helmets and trash cans (for armor!). For the helmet material, we found some clear, sheet acrylic plastic that's about 3/16" thick (thicker than the sintra "For Sale" signs I found-I wanted something a bit heavier)) and bought that. Which leads me to the reason of this post...I'm a pretty handy guy, but plastic is not my forte, hence these few questions:
1) What can I cut this stuff with? I've got a Dremel with cut-off wheels and a variable-speed jig saw with 24 TPI blades...will these work?
2) Can I heat this acrylic using the boiling water method, or should I get a heat gun?
3) What would be the best adhesive for this stuff? I bought 8 tubes of Super-Glue to start with...should I get something better? If so, what?
4) I'll be finishing these off with Bondo, but I wanna be sure to get the construction down-pat first....any tips for us noobs?
Thanks for reading, and sparing a little time to answer the silly questions of this ol' 43 year old Mandolian!