Rafal Works Helmet (RWH) v2 Helmet Templates and Build

bpwmd · Mar 31, 2015

DarkJedi3000 said:
I'm new to this and have been researching for weeks so I can make the best helmet possible. Actually i'm going to make multiple helmets using different methods. Anyways I was wondering if I could use cardstock to make this helmet? Does it have to be the 2 mm thickness? And also if I make the 2 mm thick cardboard version, can I fiberglass resin the helmet, will it have the same effects as it does on cardstcok with pepakura?

I am running into the same problem. Coming up with the supplies. I will update as possible but in some areas gluing to make the 2mm will be definitely fine an needed (ie the way the ears are designed.) But a difficulty is (from experiance) is bending 2mm stock that's been glued together. So I'm toying around with using key parts and making it work (using card stock as the shell). If you have any input or ideas please let me know as these are the absolute best plans I've found.

Sent from my iPhone

RafalFett · Mar 31, 2015

DarkJedi3000 said:
I'm new to this and have been researching for weeks so I can make the best helmet possible. Actually i'm going to make multiple helmets using different methods. Anyways I was wondering if I could use cardstock to make this helmet? Does it have to be the 2 mm thickness? And also if I make the 2 mm thick cardboard version, can I fiberglass resin the helmet, will it have the same effects as it does on cardstcok with pepakura?

You can use any method you want, but the thickness is a must, as this will ensure that the helmet will have the right form and feel.

DarkJedi3000 · Apr 1, 2015

bpwmd said:
I am running into the same problem. Coming up with the supplies. I will update as possible but in some areas gluing to make the 2mm will be definitely fine an needed (ie the way the ears are designed.) But a difficulty is (from experiance) is bending 2mm stock that's been glued together. So I'm toying around with using key parts and making it work (using card stock as the shell). If you have any input or ideas please let me know as these are the absolute best plans I've found.

Sent from my iPhone

Yeah, how did you do the cheekbone area with the cardstock? I have yet to begin building mine and am wondering if I should just glue cardstock together or just buy sintra or cardboard.

bpwmd · Apr 1, 2015

I have not built it yet. Still struggling with the stock. My recommendation is to check any local sign shops in your area. I would say if your gluing. Do not exced 2 layers. I had to glue 3 together and it's been a pain

Sent from my iPhone

BobaKen · Apr 3, 2015

I am newbie and would like to thank RafalFett for this awesome tutorial and template, been searching for something like this
for a few weeks now

RafalFett · Apr 3, 2015

BobaKen said:
I am newbie and would like to thank RafalFett for this awesome tutorial and template, been searching for something like this
for a few weeks now

Thanks alot for the nice words!

BobaKen · Apr 4, 2015

RafalFett said:
Thanks alot for the nice words!

My pleasure

Mutley · Apr 9, 2015

Again I'm flabbergasted at that amount of love and devotion is put into this. I just discovered your thread and.... WOW!
I have only 1 question. I can get my hands on a lot of Sintra and I love to work with it. Only thing is, it is 3mm thick. Could your design work if I use the 3mm instead of 2mm cardboard?

Mutley Out

RafalFett · Apr 9, 2015

Mutley said:
Again I'm flabbergasted at that amount of love and devotion is put into this. I just discovered your thread and.... WOW!
I have only 1 question. I can get my hands on a lot of Sintra and I love to work with it. Only thing is, it is 3mm thick. Could your design work if I use the 3mm instead of 2mm cardboard?

Mutley Out

Thanks for the kind words! If you will use a 3mm thick material (Sintra in your case) you will have a major problem on fitting the inner and outer layers, but also with other parts too. It will work great for the inner support pierces, but not for the layers and possibly the dome. Try to get some 2mm material if possible. If you don't strive for accuracy, then you should account for some extra material for the pieces that are interconnected (like the inner and outer layers, and possibly the dome slices).

BobaKen · May 11, 2015

Rafal, I have a question, tried my first bucket and it was a disaster...lol My issue was bending the board, I was too concerned about
over doing the spray mist, that it might get over soaked. any ideas ? Especially on the 2 mm boards

Btw, I also ordered Animefan's bucket

RafalFett · May 11, 2015

BobaKen said:
Rafal, I have a question, tried my first bucket and it was a disaster...lol My issue was bending the board, I was too concerned about
over doing the spray mist, that it might get over soaked. any ideas ? Especially on the 2 mm boards

Btw, I also ordered Animefan's bucket

I never tried the water misting method, instead I did lots of scratched strips with an empty ballpen on the back of the inner or outer layer. These strips will soften the cardboard and will let you bend the pieces with ease. You might also combine the 2 methods.

Also, PM replied.

BobaKen · May 11, 2015

Thanks for that info Rafal, I will try that method

super3 · Jul 25, 2015

The cheek pieces between right and left aren't symmetrical is this intentional or the result of some odd sizing issues from the printing?

RafalFett · Jul 25, 2015

super3 said:
The cheek pieces between right and left aren't symmetrical is this intentional or the result of some odd sizing issues from the printing?

Yes, they are different in size and form. The real helmet has this characteristic, more exactly the left and right sides is not symmetrical, even the dome has a non symmetrical shape.

super3 · Jul 26, 2015

Awesome thanks for the info I was worried I had some printing issue. So far thanks to you files and this thread things are coming along nicely.

Jedi · Aug 12, 2015

Awesome work! I'm glad there are people as smart as you to figure out this whole endeavor. I know I never could! I'm going to start a build with these templates as soon as I find some time, just wondering do you have an in-depth tutorial for dummies like me? I'm apparently not very good at this sort of thing as I have tried the WOF templates using Antmans technique 3 times and have had sizing/printing issues each time. So I am a little cautious to begin again with yours, I just am not sure where to start. I have 2mm mat/cardboard and have started to try and understand the build but my out-dated computer won't let me view some of the build images you have attached to this thread so it's hard to see what you are doing (and I am a very visual learner) sorry to keep going on and on, thanks so much again any advice will be much appreciated thanks!!!

RafalFett · Aug 13, 2015

Thanks for the kind words! The first post has all the necessary info and images for a build, but it is good to check out other's build too, as sometimes there are more than 1 way of building things.

RichHFB · Aug 14, 2015

Just clicking 'Like' on this post just doesn't do it justice I love it. Massive thank you, I have been working with the 2006 Wizard of Flight templates. Which in themselves are quite good but your improvements that make a lot of sense. So big thank you for posting

RafalFett · Aug 14, 2015

RichHFB said:
Just clicking 'Like' on this post just doesn't do it justice I love it. Massive thank you, I have been working with the 2006 Wizard of Flight templates. Which in themselves are quite good but your improvements that make a lot of sense. So big thank you for posting

Thank a lot!

ToEleven · Aug 17, 2015

Many thanks Rafal for your work on this template...It really is a masterpiece!

Rafal Works Helmet (RWH) v2 Helmet Templates and Build

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