Subscribe
  1. Stomper's Avatar
    Member Since
    Dec 2007
    Posts
    18
    Sep 1, 2008, 10:04 PM - WIP - DP95 Re-work #1

    Here's a DP95 Boba Fett helmet I am reworking into a "generic" Mando helmet. I cut the helmet in two (from left to right) and lengthened about 3/4"-1" so an adult can actually wear it without their nose being squished against the t-visor. There is still a LOT more work to do on this, but it has come a LONG WAY from where I started... it had a crack in it and a THICK layer of silver paint on it that had to be stripped off before I could do anything meaningful with it.

    I use "Plastic Fusion" (available at Home Depot) as the filler/bonder in case anyone is interested...




    OK... photos of the DP95 helmet:






    Last edited by Stomper; Sep 14, 2008 at 5:22 PM.
  2. formerly Sgt. Skirata Huntman's Avatar
    Member Since
    May 2006
    Posts
    1,186
    Sep 3, 2008, 10:00 PM - Re: WIP - DP95 Re-work #2

    nice work I can't wait to see the finished work, Especially If they are anything like your clone blasters or your imperial code cylinders. then I will definately want a helmet or more for my fan film.
    Last edited by Huntman; Sep 4, 2008 at 10:40 PM.
  3. Bubba Fett's Avatar
    Member Since
    Jul 2006
    Posts
    1,308
    Sep 4, 2008, 8:22 AM - Re: WIP - DP95 Re-work #3

    Brave man to cut that up. I tried to wear the DP95 helmet I made for my son once, and could not even put it on. So good work!
  4. sithchick's Avatar
    Member Since
    Apr 2008
    Posts
    77
    Sep 14, 2008, 11:24 PM - Re: WIP - DP95 Re-work #4

    So does it fit the typical noggin?
  5. SlabFett's Avatar
    Member Since
    Jul 2008
    Posts
    217
    Sep 17, 2008, 1:36 AM - Re: WIP - DP95 Re-work #5

    Quote sithchick said: View Post
    So does it fit the typical noggin?
    Yes, but then it is still too small for Stomper.
  6. Stomper's Avatar
    Member Since
    Dec 2007
    Posts
    18
    Sep 20, 2008, 8:43 PM - Re: WIP - DP95 Re-work #6

    LOL... Jim, S-H-U-T.... U-P!!

    I wear a 7-3/8 hat size, and there is a little room for custom padding which was my goal whn making this mod... as well as not having my nose squished up against the T-visor, which I hear seems to be a typical issue.

    I've been doing some detail work on this lately, I want as little trimming and sanding as possible when it comes from the mold.... oh yes, I'm going to be replicating this puppy!
  7. twistedxknights's Avatar
    Member Since
    Apr 2008
    Posts
    141
    Sep 21, 2008, 12:45 AM - Re: WIP - DP95 Re-work #7

    hmm.. might have to follow your lead on this one... i got a helmet i gotta fix so after i get it fixed may bisect it and extend it a bit.. would help with my nose touching the visor
  8. Sep 21, 2008, 6:09 AM - Re: WIP - DP95 Re-work #8

    Go Stomper! Lookin' good bud.
  9. Stomper's Avatar
    Member Since
    Dec 2007
    Posts
    18
    Nov 2, 2008, 7:01 PM - Re: WIP - DP95 Re-work #9

    I have been extremely busy with life, work, and continuing education for my electrical license, so it has been touch and go getting much done on this.

    I had this thing all primered and was keen to get the mold made about a month ago, but after it was painted I could see wavy/flat spots in the dome. Sanding the rotocast vinyl material is a pain because it doesn't take much to heat it up... then it just gives way under the sander and makes it worse.

    What I did was use some stuff called "Burnham's Rock Hard Water Putty", on the dome and slowly worked the sander over it.... over and over, and over, and over.... wudda pain!!

    Here's the thing fresh from the workshop sanding station...












    And here's the photos showing it to be a DP95 to quell any possible recasting issues/complaints once I get this into production. The original embossed lettering won't show up after its primered:








    I'll post more photos once its primered up, and then of the mold once I get that far.
    Last edited by Stomper; Nov 10, 2008 at 11:14 PM.
  10. Wolfi's Avatar
    Member Since
    Jan 2006
    Posts
    107
    Nov 8, 2008, 4:06 PM - Re: WIP - DP95 Re-work #10

    Quote Stomper said: View Post
    I have been extremely busy with life, work, and continuing education for my electrical license,
    Very good, sounds like we'll see some groundbreaking experiments in the "electrical field" on this helmet (LEDs, servos, new electric ringefinder concepts?)

    with force,
    wolfi
  11. Stomper's Avatar
    Member Since
    Dec 2007
    Posts
    18
    Nov 8, 2008, 5:58 PM - Re: WIP - DP95 Re-work #11

    LOL... well the way things have been going with this project, I'll be doing good just to get the flippin' thing acceptably ready to make a mold of it. It's primered, but there is a little more work to do in the helmet's left side dome.

    Initially I will just make the straight-forward generic helmet kit in gel-coat fiberglass... the end user will have to pimp it out, and currently I just simply don't have the time and energy to pursue it beyond the kit form.
  12. Stomper's Avatar
    Member Since
    Dec 2007
    Posts
    18
    Nov 10, 2008, 10:51 PM - Re: WIP - DP95 Re-work #12

    Here is the helmet after many coats of primer and wet sanding in between coats, overall I'm pretty satisfied with the results. Tomorrow is Veteran's day and I'm off work, so I'll be shooting a black semi-gloss enamel over it... most likely a few coats with wet sanding in between. My goal is to produce helemts that are as smooth as silk right from the mold that will require next to no prep work other than cutting out the rear key-holes if the end user so desires... Then I have to work out how I'm going to produce the RF stalk in aluminum (any advice is welcome!!)







  13. formerly Sgt. Skirata Huntman's Avatar
    Member Since
    May 2006
    Posts
    1,186
    Nov 10, 2008, 11:33 PM - Re: WIP - DP95 Re-work #13

    BEAUTIFuL!!!!now I know how a Jawa feels when he sees something shiny and beautiful.
    Last edited by Huntman; Nov 10, 2008 at 11:58 PM.
  14. Dman's Avatar
    Member Since
    Nov 2008
    Posts
    38
    Nov 11, 2008, 6:21 PM - Re: WIP - DP95 Re-work #14

    WOW, keep up the good work and progress reports. I just bought a DP '96 helmet and was wondering how to rework it so my big head will fit properly.
  15. Wolfi's Avatar
    Member Since
    Jan 2006
    Posts
    107
    Jul 29, 2009, 4:13 PM - Re: WIP - DP95 Re-work #15

    So how is the baby so far? any new progress on that beauty?
  16. DarthVader1's Avatar
    Member Since
    Jan 2003
    Posts
    2,462
    Sep 12, 2009, 9:41 PM - Re: WIP - DP95 Re-work #16

    Stomper, as a veteran member of TDH....I have a sugestion and "an offer you won't refuse". If you can, make the helmet flare to the sides a little bit more.....and I PROMISE, I WILL buy THE FIRST CAST out of the mold, if you do this....I swear and promise.

    Why am I saying this....simple: some guys are not exactly born with the "BULLOCK body frame", and specially NECK LENGH, including myself. Having a smaller helmet, with adapted dimensions to match those of the original.....yours looks like the call for those longing for a "NEAR-PERFECT" alternative to the one used on screen, for shorter-frame-type guys like me.

  17. Member Since
    Apr 2009
    Posts
    3
    Feb 17, 2010, 6:49 AM - Re: WIP - DP95 Re-work #17

    how much and how soon can i order
  18. SUPERprops's Avatar
    Member Since
    Nov 2009
    Posts
    442
    Feb 24, 2010, 10:34 PM - Re: WIP - DP95 Re-work #18

    Quote Stomper said: View Post

    I wear a 7-3/8 hat size, and there is a little room for custom padding which was my goal whn making this mod... as well as not having my nose squished up against the T-visor, which I hear seems to be a typical issue.
    Ohh, so you have a big nose?

    JK
    LOOKS GREAT!!!
  19. Stomper's Avatar
    Member Since
    Dec 2007
    Posts
    18
    Feb 26, 2010, 8:26 AM - Re: WIP - DP95 Re-work #19

    I finally have the mold made, I built a rotocast machine and plan to see how a helmet turns out this weekend!



    Click on the picture to see a demo of the machine in action:

  20. SUPERprops's Avatar
    Member Since
    Nov 2009
    Posts
    442
    Feb 27, 2010, 3:10 PM - Re: WIP - DP95 Re-work #20

    That was cool! do you have any templates or a guide on how to make it?

Similar Threads

  1. First Bucket - Just Got a DP95!
    By C0W13OY in forum Boba Fett Helmet
    Replies: 16
    Last Post: Mar 8, 2008, 7:47 AM
  2. Need an estimate... DP95
    By Devilstar2k2 in forum Boba Fett Helmet
    Replies: 10
    Last Post: Jan 28, 2008, 11:34 AM
  3. My DP95 with stubborn RF
    By Airman Fett in forum Boba Fett Helmet
    Replies: 10
    Last Post: Aug 1, 2006, 4:52 PM
  4. DP95 compared to MS2 and SGB
    By evan4218 in forum Boba Fett Helmet
    Replies: 4
    Last Post: Apr 25, 2006, 10:21 PM
  5. Finally got myself a DP95 :-)
    By fett-uk in forum Boba Fett Helmet
    Replies: 7
    Last Post: Aug 11, 2004, 6:50 AM