ToEleven Junior Fett scratch build WIP

ToEleven

Active Hunter

• Aug 11, 2015

• #1

Ive been working on a Rafalfett v2 based 92% scale bucket for my son, so I thought I'd share my progress for all the scratch build photo junkies like myself.

I used 2mm (.08") Sintra/ expanded pvc /closed cell pvc for construction which is a breeze compared to cardboard--I did need to work on my heat gun skills because of shrinkage :\.





The dome I have glued in here had to completely removed and redone. I didn't have my inner layer straight enough which led to problems fitting the dome in.


Bending the sections over the dome templates. I line up the front form to the #1 front section and go around each section to each corresponding form template.


Shrinkage...and the Kragle.

 

ToEleven

Active Hunter

• Aug 11, 2015

• #2

Of course bondo body filler will fix a world of problems.



...After some sanding and fixing.

Let me say that if you don't have experience with bondo, be sure to work in small batches-- because you really only have a few minutes to spread a little around. If you try to bite off too much at once you have a big goopy mess that will take hours to sand down....this stuff gets super hard.

Another thing I like to do is "shave" down the high spots with a razor blade right before the bondo sets and it's still slightly tacky. If you have to sand all that it's just more time consuming.

 

Last edited by a moderator: Aug 11, 2015

ToEleven

Active Hunter

• Aug 11, 2015

• #3

I have access to a small Shopbot cnc router, so I grabbed Rafalfett's sketchup files and reduced them to 92% for the ears, exported .stl files for Aspire (the cnc cad/cam software) and carved the ears out to scale!
View attachment 0802151640a.jpg


...after much bondoing and sanding.


...after even more sanding to get the lumps out of the dome area.

 

paucarmelbea

Hunter

• Aug 11, 2015

• #4

the results you scratch buliders get blow my mind !....amazing work !

 

polarcupz

New Hunter

• Aug 11, 2015

• #5

Wow! So smooth!
I hate working with bondo, but you have done great with it.

 

Last edited by a moderator: Jul 25, 2017

RafalFett

Well-Known Hunter

• Aug 11, 2015

• #6

Great build so far! And I love what you did to those ears! There is something funny with that dome shape, nothing major, just a bit weird looking from the sides. I think this has to be the result of not using directly the dome supports inside the helmet. But as I said, it is a minor thing and most of us will never notice, so keep up the great work and give us plenty of updates, especially updates with images.

 

ToEleven

Active Hunter

• Aug 11, 2015

• #7

Thanks for the kind words!

RafalFett said:

Great build so far! And I love what you did to those ears! There is something funny with that dome shape, nothing major, just a bit weird looking from the sides. I think this has to be the result of not using directly the dome supports inside the helmet. But as I said, it is a minor thing and most of us will never notice, so keep up the great work and give us plenty of updates, especially updates with images.

Click to expand...

Rafal, the dome has given me trouble partially because of what you said. The other problem was with the top of the side layers having a bit of a curve to them (my fault again). Anyway, my son is only 7 and thinks it's amazing so I'll probably let it go. I'm going to get a 2nd one built up pretty soon for his little brother--and I'll know what to look out for, so maybe it will shape up better than this one. Who knows if I can get it close enough I may try casting it!

 

B

beetle

Jr Hunter

• Aug 11, 2015

• #8

Super clean work, nice job!

 

ToEleven

Active Hunter

• Aug 13, 2015

• #9

I broke down and did a little more sculpting on the dome...still not perfect, but I'm happier with it I think.


Here's where I'm at with my ears...

 

RafalFett

Well-Known Hunter

• Aug 13, 2015

• #10

There's a noticeable difference on the dome and I love it! And love those ears too!

 

ToEleven

Active Hunter

• Aug 18, 2015

• #11

I cnc routed the range finder stalk from 1/4" aluminum sheet stock.



Range finder glued up, sanded and primed.



Mounted stalk with tapped screw holes.




I'm about ready to start painting. I need to drill for the borden, attach the right ear cap, make the plexi/perspex block...and my son wants the PP1 "eyes" look so I need to add the gash instead of a dent.

 

MilenkoFett

New Hunter

• Aug 18, 2015

• #12

That's an awesome jr lid!

 

machineAfett

Active Hunter

• Aug 19, 2015

• #13

This look awesome.

- - - Updated - - -

Looks awesome.

 

ToEleven

Active Hunter

• Aug 19, 2015

• #14

Thanks so much!

 

ToEleven

Active Hunter

• Aug 20, 2015

• #15

Test fitting the rangefinder housing to the stalk. I couldn't really find a photo of someone doing this, so I thought I would post this pic of my interpretation of it.

Even with 4-40 bolts it's a tight fit with the smaller size I'm working with. I had to use some filed down needlenose pliers to get the nut on the right tightened. I used a washer on the left...the right side was too tight to fit one.

 

ToEleven

Active Hunter

• Aug 21, 2015

• #16

Humbrol Bright Silver 11 airbrushed on the helmet (also wire wooled). Testors Silver Enamel on the ears.

I also added the PP1 damage.

 

polarcupz

New Hunter

• Aug 21, 2015

• #17

Nice job bolting the rangefinder instead of just gluing it. :cool

 

ToEleven

Active Hunter

• Aug 22, 2015

• #18

On to the back panels! My attempt at the PP1 scheme. I'm not really going for 100%...I mainly want to capture the "coolness" of it.


Used a little of the #79 to muck up the ears...they can't be TOO shiny.



Good ole Humbrol Maskol and an airbrush. Just using ESB colors/ Rafalfett templates...

 

B

beetle

Jr Hunter

• Aug 23, 2015

• #19

Nice bro!
I wish I could work that fast. I think you could scratch build three helmets by the time I finish one.

 

ToEleven

Active Hunter

• Aug 23, 2015

• #20

beetle, thanks! I'm really spending waaaay to much time on this, but I can't wait to see it finished. I forget how much time each step takes though. :wacko

 

Last edited by a moderator: Jul 8, 2017