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.

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.



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

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

Awesome start! Keep up the great work!

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

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

Sweet!

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.

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.

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

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.

That is just incredible!

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!

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.......

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.

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.

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!

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.

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

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.