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WIP: First helmet build, using sheet metal

  1. #1

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    WIP: First helmet build, using sheet metal

    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. img_20130130_223503-jpg

    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.

    img_20130217_142110-jpgimg_20130309_152604-jpgimg_20130224_172941-jpgimg_20130309_163803-jpgimg_20130310_171757-jpgimg_20130310_171804-jpgimg_20130310_171813-jpgimg_20130317_173532-jpg

    Still a work in progress, I'll get more posted up as I go along.
    Enjoy.

  2. #2

    Re: WIP: First helmet build, using sheet metal

    wow, thats pretty ******, how much do you think it will weigh??

  3. #3
    RafalFett's Avatar
    Member Since
    Oct 2010
    From
    Galati, Romania
    Posts
    2,623

    Re: WIP: First helmet build, using sheet metal

    Awesome start! Keep up the great work!

  4. #4

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    It'll probably weigh a few lbs. I'll weigh it once it's all put together. Super sturdy though, lol

  5. #5

    Re: WIP: First helmet build, using sheet metal

    I don't think I've ever seen anyone do it this way. That's pretty impressive.

  6. #6

    Re: WIP: First helmet build, using sheet metal

    Sweet!

  7. #7

    Member Since
    Jul 2011
    From
    Orlando, Florida
    Posts
    32

    Re: WIP: First helmet build, using sheet metal

    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.

  8. #8

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.
    Attached Thumbnails Attached Thumbnails img_20130323_181703-jpg   img_20130323_181654-jpg   img_20130324_193553-jpg  


  9. #9
    xose421's Avatar
    Member Since
    Mar 2013
    From
    Puerto Rico
    Posts
    23

    Re: WIP: First helmet build, using sheet metal

    This looks so awesome... can't wait to see it finish and polished up.

  10. #10

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.
    Attached Thumbnails Attached Thumbnails img_20130331_163754-jpg   img_20130331_163805-jpg   img_20130331_163828-jpg  

    img_20130331_163834-jpg  

  11. #11

    Re: WIP: First helmet build, using sheet metal

    That is just incredible!

  12. #12
    RafalFett's Avatar
    Member Since
    Oct 2010
    From
    Galati, Romania
    Posts
    2,623

    Re: WIP: First helmet build, using sheet metal

    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!

  13. #13

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.......

  14. #14
    darkartist81's Avatar
    Member Since
    Mar 2013
    From
    Dunnellon, FL
    Posts
    184

    Re: WIP: First helmet build, using sheet metal

    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.

  15. #15

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.

  16. #16
    WookieeHunter's Avatar
    Member Since
    Apr 2013
    From
    Lincolnshire, UK
    Posts
    9

    Re: WIP: First helmet build, using sheet metal

    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!

  17. #17

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.

    img_20130428_172253-jpgimg_20130428_172425-jpgimg_20130428_172349-jpg

  18. #18
    Syper's Avatar
    Member Since
    Oct 2008
    From
    Fremont, CA
    Posts
    732

    Re: WIP: First helmet build, using sheet metal

    Amazing Craftsmanship!!! Thank you for sharing this build with us.

  19. #19

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.

  20. #20

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.

    imag0137-jpgimag0136-jpgimag0135-jpgimag0134-jpgimag0133-jpg

  21. #21

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.

    imag0144-jpgimag0146-jpgimag0145-jpg

  22. #22

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.
    imag0207-jpgimag0227-jpgimag0228-jpgimag0224-jpg

  23. #23

    Member Since
    Feb 2013
    From
    California
    Posts
    31

    Re: WIP: First helmet build, using sheet metal

    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.

  24. #24
    Jigglenomicon's Avatar
    Member Since
    Mar 2013
    From
    Denmark
    Posts
    167

    Re: WIP: First helmet build, using sheet metal

    This is super awesome!
    i hope you have a really strong neck tho , that thing must weigh a ton ^^

  25. #25

    Re: WIP: First helmet build, using sheet metal

    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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