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  1. ToEleven's Avatar
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    3 Weeks Ago - Aug 11, 2015, 9:59 AM - ToEleven Junior Fett scratch build WIP #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 :\.

    0629152242-jpg0629152242a-jpg0629152243-jpg0629152248-jpg0630152107-jpg

    0707152043-custom-jpg0704151340-custom-jpg

    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.

    0721152151-jpg
    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.

    0721152303-jpg
    Shrinkage...and the Kragle.
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  3. ToEleven's Avatar
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    3 Weeks Ago - Aug 11, 2015, 10:08 AM - Re: ToEleven Junior Fett scratch build WIP #2

    Of course bondo body filler will fix a world of problems.
    0725152049-jpg0725152049a-jpg

    0802151510-jpg0802151929-jpg
    ...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 ToEleven; 3 Weeks Ago at 10:17 AM.
  4. ToEleven's Avatar
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    3 Weeks Ago - Aug 11, 2015, 10:29 AM - Re: ToEleven Junior Fett scratch build WIP #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!
    0802151640a-jpg

    0808152145-jpg0808152146-jpg0808152146a-jpg0808152146b-jpg
    ...after much bondoing and sanding.

    0810151241a-jpg0810151242-jpg
    ...after even more sanding to get the lumps out of the dome area.
  5. paucarmelbea's Avatar
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    3 Weeks Ago - Aug 11, 2015, 10:58 AM - Re: ToEleven Junior Fett scratch build WIP #4

    the results you scratch buliders get blow my mind !....amazing work !
  6. polarcupz's Avatar
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    3 Weeks Ago - Aug 11, 2015, 11:05 AM - Re: ToEleven Junior Fett scratch build WIP #5

    Wow! So smooth!
    I hate working with bondo, but you have done great with it.
  7. RafalFett's Avatar
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    3 Weeks Ago - Aug 11, 2015, 11:24 AM - Re: ToEleven Junior Fett scratch build WIP #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.
  8. ToEleven's Avatar
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    3 Weeks Ago - Aug 11, 2015, 1:08 PM - Re: ToEleven Junior Fett scratch build WIP #7

    Thanks for the kind words!

    Quote RafalFett said: View Post
    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.
    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!
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    3 Weeks Ago - Aug 11, 2015, 4:02 PM - Re: ToEleven Junior Fett scratch build WIP #8

    Super clean work, nice job!
  10. ToEleven's Avatar
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    3 Weeks Ago - Aug 13, 2015, 9:53 AM - Re: ToEleven Junior Fett scratch build WIP #9

    I broke down and did a little more sculpting on the dome...still not perfect, but I'm happier with it I think.
    0812151242-jpg0812151242a-jpg

    Here's where I'm at with my ears...
    0812151253-jpg
  11. RafalFett's Avatar
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    2 Weeks Ago - Aug 13, 2015, 10:54 AM - Re: ToEleven Junior Fett scratch build WIP #10

    There's a noticeable difference on the dome and I love it! And love those ears too!
  12. ToEleven's Avatar
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    2 Weeks Ago - Aug 18, 2015, 3:10 PM - Re: ToEleven Junior Fett scratch build WIP #11

    I cnc routed the range finder stalk from 1/4" aluminum sheet stock.
    0815151541-jpg0815151601-jpg


    Range finder glued up, sanded and primed.
    0817152051-jpg0817152220-jpg0817152257-jpg


    Mounted stalk with tapped screw holes.
    0818151402a-jpg0818151403-jpg0818151403a-jpg



    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.
  13. MilenkoFett's Avatar
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    2 Weeks Ago - Aug 18, 2015, 3:59 PM - Re: ToEleven Junior Fett scratch build WIP #12

    That's an awesome jr lid!
  14. Member Since
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    2 Weeks Ago - Aug 19, 2015, 12:42 PM - Re: ToEleven Junior Fett scratch build WIP #13

    This look awesome.

    - - - Updated - - -

    Looks awesome.
  15. ToEleven's Avatar
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    2 Weeks Ago - Aug 19, 2015, 8:30 PM - Re: ToEleven Junior Fett scratch build WIP #14

    Thanks so much!
  16. ToEleven's Avatar
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    2 Weeks Ago - Aug 20, 2015, 9:02 AM - Re: ToEleven Junior Fett scratch build WIP #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.

    0818152328-jpg
  17. ToEleven's Avatar
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    1 Week Ago - Aug 21, 2015, 1:47 PM - Re: ToEleven Junior Fett scratch build WIP #16

    0821151243a-jpg0821151244-jpg0821151245-jpg0821151249-jpg

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

    I also added the PP1 damage.
  18. polarcupz's Avatar
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    1 Week Ago - Aug 21, 2015, 2:14 PM - Re: ToEleven Junior Fett scratch build WIP #17

    Nice job bolting the rangefinder instead of just gluing it.
  19. ToEleven's Avatar
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    1 Week Ago - Aug 22, 2015, 8:51 PM - Re: ToEleven Junior Fett scratch build WIP #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.

    0821152151-jpg
    Used a little of the #79 to muck up the ears...they can't be TOO shiny.


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    Good ole Humbrol Maskol and an airbrush. Just using ESB colors/ Rafalfett templates...
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    1 Week Ago - Aug 23, 2015, 4:28 PM - Re: ToEleven Junior Fett scratch build WIP #19

    Nice bro!
    I wish I could work that fast. I think you could scratch build three helmets by the time I finish one.
  21. ToEleven's Avatar
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    1 Week Ago - Aug 23, 2015, 9:36 PM - Re: ToEleven Junior Fett scratch build WIP #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.
  22. ToEleven's Avatar
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    1 Week Ago - Aug 24, 2015, 8:45 PM - Re: ToEleven Junior Fett scratch build WIP #21

    More progress! My wife is politely tolerating this...bless her.

    0823152045a-jpg0824152131-jpg0824152131a-jpg0824152132-jpg
    Humbrol 79 layer, 78 dome/cheeks, black cheeks and eyes to boot!
  23. RafalFett's Avatar
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    1 Week Ago - Aug 25, 2015, 12:36 AM - Re: ToEleven Junior Fett scratch build WIP #22

    Wow! Really love the paint job on that helmet. And I like that you chose to do that light green on the dome and lower cheeks. Just a side note: I'm not that sure anymore that the rear keyhole has that orange color, maybe it is silver/metal, similar to the Sandy type helmets - Pre-Pro #2, Promo #2 and ROTJ. Also the right ear (rangefinder side) is not green but dark gray. ...I have to update those stencils.
  24. ToEleven's Avatar
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    1 Week Ago - Aug 25, 2015, 7:21 AM - Re: ToEleven Junior Fett scratch build WIP #23

    Quote RafalFett said: View Post
    Wow! Really love the paint job on that helmet. And I like that you chose to do that light green on the dome and lower cheeks. Just a side note: I'm not that sure anymore that the rear keyhole has that orange color, maybe it is silver/metal, similar to the Sandy type helmets - Pre-Pro #2, Promo #2 and ROTJ. Also the right ear (rangefinder side) is not green but dark gray. ...I have to update those stencils.
    Thanks for the kind words! That's interesting about the colors...I really wish that there were more photos taken of the PP1 helmet. I guess they had no idea we would all be trying to reproduce it someday!
  25. RafalFett's Avatar
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    1 Week Ago - Aug 25, 2015, 11:56 AM - Re: ToEleven Junior Fett scratch build WIP #24

    Quote ToEleven said: View Post
    Thanks for the kind words! That's interesting about the colors...I really wish that there were more photos taken of the PP1 helmet. I guess they had no idea we would all be trying to reproduce it someday!
    Here are the new colors that I think are closer to the real one (I used these colors for my 3D model), but still not sure about the rear keyhole color:

    helmet-gash-01-jpg helmet-gash-05-jpg helmet-gash-02-jpg helmet-gash-03-jpg helmet-gash-04-jpg helmet-gash-06-jpg helmet-gash-08-jpg helmet-gash-07-jpg

    And the images I used as a guide:

    boba-fett-costume-first-prototype-san-anselmo-parade-04a-jpg fett-1980-jpg

    Here is the back of the helmet from the San Anselmo parade, but the quality is poor:

    pp1-033-jpg
  26. ToEleven's Avatar
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    1 Week Ago - Aug 25, 2015, 1:40 PM - Re: ToEleven Junior Fett scratch build WIP #25

    Oh sweet! I see what you mean. Thanks for digging these up! At this point I'm thinking about going back and redoing the keyhole. I'm really wanting to see some kill stripes on there 1st though.

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