WIP - DP95 Re-work

  1. #1

    WIP - DP95 Re-work

    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. #2
    formerly Sgt. Skirata Huntman's Avatar
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    May 2006
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    1,186

    Re: WIP - DP95 Re-work

    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. #3
    Bubba Fett's Avatar
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    Jul 2006
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    SF Bay Area, CA
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    Re: WIP - DP95 Re-work

    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. #4
    sithchick's Avatar
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    Apr 2008
    From
    post Falls Idaho
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    Re: WIP - DP95 Re-work

    So does it fit the typical noggin?

  5. #5
    SlabFett's Avatar
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    Jul 2008
    From
    Banks, Oregon
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    Re: WIP - DP95 Re-work

    sithchick said: View Post
    So does it fit the typical noggin?
    Yes, but then it is still too small for Stomper.

  6. #6

    Re: WIP - DP95 Re-work

    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. #7
    twistedxknights's Avatar
    Member Since
    Apr 2008
    From
    Makakilo City, Hawaii, United States
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    141

    Re: WIP - DP95 Re-work

    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. #8

    Re: WIP - DP95 Re-work

    Go Stomper! Lookin' good bud.

  9. #9

    Re: WIP - DP95 Re-work

    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. #10

    Re: WIP - DP95 Re-work

    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. #11

    Re: WIP - DP95 Re-work

    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. #12

    Re: WIP - DP95 Re-work

    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. #13
    formerly Sgt. Skirata Huntman's Avatar
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    May 2006
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    1,186

    Re: WIP - DP95 Re-work

    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. #14
    Dman's Avatar
    Member Since
    Nov 2008
    From
    Norwich, CT.
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    38

    Re: WIP - DP95 Re-work

    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. #15

    Re: WIP - DP95 Re-work

    So how is the baby so far? any new progress on that beauty?

  16. #16
    DarthVader1's Avatar
    Member Since
    Jan 2003
    From
    Phenix City, AL
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    2,462

    Re: WIP - DP95 Re-work

    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. #17

    Member Since
    Apr 2009
    From
    Brisbane, Australia
    Posts
    3

    Re: WIP - DP95 Re-work

    how much and how soon can i order

  18. #18

    Re: WIP - DP95 Re-work

    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. #19

    Re: WIP - DP95 Re-work

    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. #20

    Re: WIP - DP95 Re-work

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

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