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  1. Member Since
    Feb 2013
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    33
    Mar 17, 2013, 8:27 PM - WIP: First helmet build, using sheet metal #1

    Hello guys,
    First time attempting to build a helmet of any kind. Made the first test fit helmet out of paper, just to see how well it fit. Turned out to be a bit too small for me so I scaled the whole thing up 3%. Worked out nice.

    First up is the paper one scaled up. Click image for larger version. 

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    Then I used sticker paper to print out the templates (thank you everyone who has created templates and posted them to share, KUDOS!!!)
    Used an electric disc cutter and a jig saw to get then all cut out.

    Click image for larger version. 

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    Still a work in progress, I'll get more posted up as I go along.
    Enjoy.
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  3. Member Since
    May 2008
    Posts
    6
    Mar 17, 2013, 9:15 PM - Re: WIP: First helmet build, using sheet metal #2

    wow, thats pretty ******, how much do you think it will weigh??
  4. RafalFett's Avatar
    Member Since
    Oct 2010
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    Mar 18, 2013, 8:43 AM - Re: WIP: First helmet build, using sheet metal #3

    Awesome start! Keep up the great work!
  5. Member Since
    Feb 2013
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    33
    Mar 18, 2013, 2:59 PM - Re: WIP: First helmet build, using sheet metal #4

    It'll probably weigh a few lbs. I'll weigh it once it's all put together. Super sturdy though, lol
  6. IceCreamKid's Avatar
    Member Since
    Mar 2013
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    17
    Mar 18, 2013, 4:53 PM - Re: WIP: First helmet build, using sheet metal #5

    I don't think I've ever seen anyone do it this way. That's pretty impressive.
  7. Member Since
    Dec 2012
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    78
    Mar 18, 2013, 10:00 PM - Re: WIP: First helmet build, using sheet metal #6

    Sweet!
  8. Member Since
    Jul 2011
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    32
    Mar 21, 2013, 11:11 PM - Re: WIP: First helmet build, using sheet metal #7

    I've always wanted a Boba Fett helmet that was made of steel or even bulletproof like a soldiers helmet. A full field grade suit would be the ultimate dream haha.

    Keep it up. Can't wait to see the finished look.
  9. Member Since
    Feb 2013
    Posts
    33
    Mar 25, 2013, 3:29 AM - Re: WIP: First helmet build, using sheet metal #8

    Thanks guys, haven't had the most time to work on my helmet. I did get all the pieces cut out and spent some time on the keyhole thingie for the back.
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  10. xose421's Avatar
    Member Since
    Mar 2013
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    Mar 28, 2013, 3:12 PM - Re: WIP: First helmet build, using sheet metal #9

    This looks so awesome... can't wait to see it finish and polished up.
  11. Member Since
    Feb 2013
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    33
    Mar 31, 2013, 8:13 PM - Re: WIP: First helmet build, using sheet metal #10

    Got the left ear piece done, started to work on the range finder. All of it is still in the very rough mock up stage.
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  12. Wolfsburg's Avatar
    Member Since
    Dec 2012
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    Apr 1, 2013, 12:45 AM - Re: WIP: First helmet build, using sheet metal #11

    That is just incredible!
  13. RafalFett's Avatar
    Member Since
    Oct 2010
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    3,206
    Apr 1, 2013, 11:35 AM - Re: WIP: First helmet build, using sheet metal #12

    WOW! You did a great job with my helmet templates! I know that is a bit hard to do the ears and the rangefinder from scratch (using cardboard or sintra), but seeing that you did all this using metal sheets, you have my deepest respect and admiration! Just keep up with the already awesome work!
  14. Member Since
    Feb 2013
    Posts
    33
    Apr 2, 2013, 12:27 AM - Re: WIP: First helmet build, using sheet metal #13

    Yeah, they are super tricky. I get a bit anal about the evenness and proportions, so I've been grinding and doing filler welds, then grinding those down. My range finder "mast" is a bit off, so I might redo that one. It's actually going pretty well, no huge snags yet, but it's still early. Funnest project I've done in a while. Thanks for the support, it's really keeping the motivation going.

    Keep on keepin' on.......
  15. darkartist81's Avatar
    Member Since
    Mar 2013
    Posts
    190
    Apr 6, 2013, 10:32 AM - Re: WIP: First helmet build, using sheet metal #14

    This is amazing... I can't believe you are doing this with sheet metal. Serious credit for tackling something like this, and for being so **** good at it. I really looks fantastic so far.
  16. Member Since
    Feb 2013
    Posts
    33
    Apr 15, 2013, 10:40 PM - Re: WIP: First helmet build, using sheet metal #15

    Haven't abandoned the project, just had to put it on the back burner for a bit. I'll be doing some work on it this week.
  17. Apr 22, 2013, 6:33 AM - Re: WIP: First helmet build, using sheet metal #16

    That is incredible work so far. Going to be keeping a close eye on this thread for sure, have been thinking of doing the same thing but with aluminium as i have loads at home, have started doing some mock up body armour to see how i gt on. Think its time to print out some templates though. Inspiring stuff, respect to you sir!
  18. Member Since
    Feb 2013
    Posts
    33
    Apr 28, 2013, 10:05 PM - Re: WIP: First helmet build, using sheet metal #17

    Aluminum would be awesome, go for it!

    A tiny update, I just welded a few seams. The helmet has taken the back burner for a while. But It'll get a good go next week.

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  19. Syper's Avatar
    Member Since
    Oct 2008
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    May 1, 2013, 8:55 AM - Re: WIP: First helmet build, using sheet metal #18

    Amazing Craftsmanship!!! Thank you for sharing this build with us.
  20. Member Since
    Feb 2013
    Posts
    33
    May 6, 2013, 2:09 AM - Re: WIP: First helmet build, using sheet metal #19

    Was doing some touch ups and tacking some spots on the dome, then I realized I made the lower "ear" section below the range finder backwards!!!!!!! haha, minor set back, I'll get a better one made as soon as I get the time.

    Quick tip, don't rush and always double check before doing permanent work.
  21. Member Since
    Feb 2013
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    Jun 23, 2013, 3:02 AM - Re: WIP: First helmet build, using sheet metal #20

    Ok, it's been some time now. Didn't abandon the project, other things had to come first. Anywho, go the dome slightly tacked to the bucket, the left ear tacked up, remade the right ear piece correctly, and test fit one of the computer chip boards in the keyhole thingie.

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  22. Member Since
    Feb 2013
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    Jun 24, 2013, 1:06 AM - Re: WIP: First helmet build, using sheet metal #21

    Got a little bit more done today. Box to add onto the keyhole section to allow it to recess into the helmet a tad, more tacking and adjusting the dome to the bucket, range finder lower ear piece tacked up.

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  23. Member Since
    Feb 2013
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    33
    Jul 23, 2013, 12:23 AM - Re: WIP: First helmet build, using sheet metal #22

    I have a bunch of pictures, but have to get them all organized. So here are a few of the most significant ones. Still need to do more of the detail, but that will be done a little later. First picture is after I used a torch to burn off all of the remaining stickers.
    Click image for larger version. 

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  24. Member Since
    Feb 2013
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    33
    Jul 31, 2013, 2:30 AM - Re: WIP: First helmet build, using sheet metal #23

    Now in the plans are some goodies. The suit is next. After much thinking and balancing on the fence about this, I've fallen off to the side of using sheet metal for the armor as well. Again, all of my work has been made much easier thanks to all of the hard work of all those that have put in the time and effort into creating templates. Thank you guys.
  25. Jigglenomicon's Avatar
    Member Since
    Mar 2013
    Posts
    189
    Aug 3, 2013, 6:25 PM - Re: WIP: First helmet build, using sheet metal #24

    This is super awesome!
    i hope you have a really strong neck tho , that thing must weigh a ton ^^
  26. Member Since
    Jun 2010
    Posts
    8
    Sep 9, 2013, 10:10 PM - Re: WIP: First helmet build, using sheet metal #25

    Thats what i plan to do next. My armor is already metal but my plaster\bondo\beerbox lid suffered catostrophic dent enlargment. i,ll post some pics of my plates. what did you ddo the welding with. what guage and what mat.?

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