Subscribe
  1. Member Since
    Nov 2006
    Posts
    39
    Nov 1, 2006, 10:31 PM - steel helmet? #1

    I've been skimming through threads to see figure out the dimensions of the helmet and whatnot... but i havent really seen anything made from steel or aluminum... has anyone done this before? if so how did you handle the shaping?
  2. Darth Fett's Avatar
    Member Since
    Dec 2005
    Posts
    191
    Nov 1, 2006, 10:54 PM - Re: steel helmet? #2

    i think somone has but i dont know who. you can search for it useing the search feature.
  3. I helped at SDCC '08 GCNgamer128's Avatar
    Member Since
    Jan 2006
    Posts
    5,520
    Nov 1, 2006, 11:39 PM - Re: steel helmet? #3

    Quote Faelan said: View Post
    I've been skimming through threads to see figure out the dimensions of the helmet and whatnot... but i havent really seen anything made from steel or aluminum... has anyone done this before? if so how did you handle the shaping?
    Yes, it has been done before, but I don't believe they are for sale. There have been some people to aluminum cold cast helmets though.
  4. Gilmortar's Avatar
    Member Since
    Jun 2002
    Posts
    1,747
    Nov 2, 2006, 12:06 AM - Re: steel helmet? #4

    Hand Schaub made the all metal helmets
  5. I helped at SDCC '08 Jimmy BufFETT's Avatar
    Member Since
    Apr 2006
    Posts
    2,861
    Nov 2, 2006, 12:17 AM - Re: steel helmet? #5

    Just outta curiosity, what would ya do with a metal helmet? Would it be for display, or for trooping? Reason I ask is because it's got to weigh quite a bit.
    The only reason I would want one is if I could get my :jet pack working!!!!!
  6. Member Since
    Nov 2006
    Posts
    39
    Nov 2, 2006, 12:19 AM - Re: steel helmet? #6

    becasue i dont believe in substitutes
  7. I helped at SDCC '08 Jimmy BufFETT's Avatar
    Member Since
    Apr 2006
    Posts
    2,861
    Nov 2, 2006, 12:21 AM - Re: steel helmet? #7

    Quote Faelan said: View Post
    becasue i dont believe in substitutes
    Gotcha ... very interesting!
  8. cal196's Avatar
    Member Since
    Aug 2004
    Posts
    2,617
    Nov 2, 2006, 1:10 AM - Re: steel helmet? #8

    Actually I think an Aluminum bucket wouldnt weigh that much, no?
  9. I helped at SDCC '08 GCNgamer128's Avatar
    Member Since
    Jan 2006
    Posts
    5,520
    Nov 2, 2006, 1:11 AM - Re: steel helmet? #9

    Quote cal196 said: View Post
    Actually I think an Aluminum bucket wouldnt weigh that much, no?
    I don't think so, it is hallow and would probably be 3mm thick...
  10. cal196's Avatar
    Member Since
    Aug 2004
    Posts
    2,617
    Nov 2, 2006, 1:14 AM - Re: steel helmet? #10

    but still its not that dense, You can lift an Aluminum Engine block by yourself. I dont see it weighing any more than thick fiberglass.
  11. I helped at SDCC '08 GCNgamer128's Avatar
    Member Since
    Jan 2006
    Posts
    5,520
    Nov 2, 2006, 1:15 AM - Re: steel helmet? #11

    Quote cal196 said: View Post
    but still its not that dense, You can lift an Aluminum Engine block by yourself. I dont see it weighing any more than than thick fiberglass.
    I think you over estimate me
  12. Member Since
    Aug 2006
    Posts
    130
    Nov 2, 2006, 7:49 AM - Re: steel helmet? #12

    A helmet could quite easily be welded up from Aluminum sheet. You could use 3003-H14, 6061-0 or even an 1100 series alloy. 1100 series Aluminum would be a bit soft, especially after welding. I'd probably use 6061-0 as it's a bit harder after welding and it's still pretty easy to shape. You can buy a 4ft. square sheet of .080 (about 2mm thick) for under $75. A sheet that big only weighs 1.13 lbs. so the helmet would be pretty darn light. Either way I'd TIG weld it but it could be gas welded too. Gas welding would make for more ductile joints if you have to do any shaping after welding.

    If you wanted to make the helmet more durable just have it heat treated after welding to T6 condition- it will be very durable I assure you. Worst case scenario you might have a weld crack (because the welds would have to be ground down for appearance) if you dropped it off the roof of a house. Otherwise any dents from dropping it could most likely be pounded back out. Sometimes you have to worry about cracking with 6061-T6 as it work hardens very rapidly.

    For steel, I'd go mild steel and wall thickness definitely not over 18ga. otherwise it would weigh a ton. It would be very durable. I once welded up a Ghostbusters proton pack wand from 16ga. steel and you could have thrown that thing out of an airplane and not hurt it. Check out the pics.....

    Either way you'll have to make a hardwood form for the dome and cheek sections to hammerform the metal. Aluminum is MUCH easier to form but the helmet curves really aren't that bad all things considered.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	Weldedgunbodya.jpg 
Views:	239 
Size:	34.2 KB 
ID:	13733   Click image for larger version. 

Name:	Weldedgunbodyb.jpg 
Views:	260 
Size:	37.1 KB 
ID:	13734   Click image for larger version. 

Name:	Weldedgunbodyc.jpg 
Views:	262 
Size:	38.1 KB 
ID:	13735  

    Click image for larger version. 

Name:	Weldedgunbody5.jpg 
Views:	265 
Size:	58.4 KB 
ID:	13736  
  13. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Nov 2, 2006, 7:58 AM - Re: steel helmet? #13

    Honus my friend, you have some serious skillz.
  14. Member Since
    Aug 2006
    Posts
    130
    Nov 2, 2006, 8:28 AM - Re: steel helmet? #14

    Thanks! I endeavor to satisfy...
  15. I helped at SDCC '08 Jimmy BufFETT's Avatar
    Member Since
    Apr 2006
    Posts
    2,861
    Nov 2, 2006, 9:40 AM - Re: steel helmet? #15

    Weight is gonna depend on two things: material density and volume of material used. So yes it depends on how thick the helmet is.
  16. joshcube's Avatar
    Member Since
    Oct 2006
    Posts
    59
    Nov 2, 2006, 12:02 PM - Re: steel helmet? #16

    Here is a thread on a sheet metal helmet:

    http://www.thedentedhelmet.com/showt...ht=sheet+metal

    I'm thinking of using his dome building method on my sintra bucket, since it looks much easier than cutting and bending wof's template.

Similar Threads

  1. Full steel formed dished and welded helmet
    By TD-4242 in forum Boba Fett Helmet
    Replies: 75
    Last Post: Jan 28, 2010, 9:59 PM
  2. 32 Guage Steel Boba helmet underway!. . .Mabey. .
    By Clone #8675309 in forum Boba Fett Helmet
    Replies: 11
    Last Post: Dec 8, 2009, 3:06 AM
  3. 0000 Steel Wool
    By psydaz in forum Prop Building Workshop
    Replies: 4
    Last Post: Apr 16, 2009, 12:26 AM
  4. Steel Boba helmet. Almost finished!!!!
    By Clone #8675309 in forum Boba Fett Helmet
    Replies: 15
    Last Post: Apr 28, 2006, 3:26 PM