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  1. CaptJono's Avatar
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    Jan 2005
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    Jun 13, 2009, 10:54 AM - Re: Australian Jango Progress #101

    Hey Guys, thanks for the kind words, I'm working on getting it done!
    RunJEDIrun has started & finished his Jango while I have been toying with Helmets, but I think the finish is near.

    I have been spending some time on the edges of the helmet, evening-out the thickness of the cast & beefing it up slightly.
    Still more sanding to be done, the pics will explain it better.

    I have also ground-down a few Chicago screws, cant find the posts Cruzer recommended so I'll see how I go.

    More soon.
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  2. Member Since
    Jun 2009
    Posts
    22
    Jun 16, 2009, 3:42 AM - Re: Australian Jango Progress #102

    This is definitly one of the best fett outfits I have seen. Good chance one of the most expensive in the end too lol. Great job cant wait to see the finished product!
  3. CaptJono's Avatar
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    Jan 2005
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    Sep 20, 2009, 10:19 AM - Re: Australian Jango Progress #103

    Long time, no post....
    Very little spare time of late.

    I did get a chance to do some work on the visor.

    Still some tweaking to go, but close.
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  4. Cruzer's Avatar
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    Sep 22, 2009, 6:48 PM - Re: Australian Jango Progress #104

    Nice job. Very clean.
  5. CaptJono's Avatar
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    Oct 27, 2009, 4:16 AM - Re: Australian Jango Progress #105

    Thanks Cruzer.
    (OK, I have shaped my Visor a little further since, but now its done!)

    I have also sanded-back my cold cast helmet, but I haven't polished it yet.
    It looks great form a distance, but when you get close, not so much.
    Its my first Cold Cast item, so I'm feeling my way on this one.
    There are a few problem areas where I haven't been able to sand-out imperfections without having hit the darker 2nd CC coat.
    I have included a few pics.

    The funny thing is, I can get a better finish with RubnBuff, it's finish stands-up to the closest of inspections.

    Anyway, have a few pics!
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  6. Cruzer's Avatar
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    Aug 2004
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    Oct 27, 2009, 4:02 PM - Re: Australian Jango Progress #106

    In my experience with cold casting, the darker areas can be caused by excessive sanding or insufficient aluminum content in the mixture, and is more prevalent on vertical surfaces when casting. However, you're not going to get the accustomed shiny finish that's produced with Rub n' Buff because it's a wax. The cold cast will be more dull and should have the screen accurate abraised metal look to it.

    Regardless, I don't want you to be stuck with a helmet your not happy with. Feel free to return the helmet for a full refund. I can also offer to cast you another helmet with a higher aluminum content if you want to see if you get better results. Either way, just let me know.
  7. Dark-Side's Avatar
    Member Since
    Jul 2005
    Posts
    735
    Oct 27, 2009, 5:03 PM - Re: Australian Jango Progress #107

    Quote Cruzer said: View Post
    In my experience with cold casting, the darker areas can be caused by excessive sanding or insufficient aluminum content in the mixture, and is more prevalent on vertical surfaces when casting. However, you're not going to get the accustomed shiny finish that's produced with Rub n' Buff because it's a wax. The cold cast will be more dull and should have the screen accurate abraised metal look to it.
    Totaly agree with it!
  8. FettOfficer's Avatar
    Member Since
    Oct 2005
    Posts
    803
    Oct 27, 2009, 5:54 PM - Re: Australian Jango Progress #108

    Nooo! Don't return the helmet. The CC helmet is awesome. Can't get any better than this
  9. CaptJono's Avatar
    Member Since
    Jan 2005
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    336
    Oct 27, 2009, 8:55 PM - Re: Australian Jango Progress #109

    Quote Cruzer said: View Post
    Regardless, I don't want you to be stuck with a helmet your not happy with. Feel free to return the helmet for a full refund. I can also offer to cast you another helmet with a higher aluminum content if you want to see if you get better results. Either way, just let me know.
    Hey Cruzer, just to be clear, your gear ROCKS!
    I Have no problem with your craftsmanship & I thank you for your offer, but I'll stick with this Helmet.

    Its just the close-up look of the CC that is letting me down, see 3rd pic in my previous post. I can RubnBuff a much more consistent finish & dull it down as needed.
    Does anyone else with CC items know/see what I'm talking about?
  10. I helped at SDCC '08 Jango 5204's Avatar
    Member Since
    Nov 2005
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    1,376
    Oct 27, 2009, 9:31 PM - Re: Australian Jango Progress #110

    I found it to not be as uniform of an appearance in some places, but it grows on you. When next to R&B I feel it looks far better. The variations give it a "real world" look. I prefer the cold cast look now.
  11. CaptJono's Avatar
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    Jan 2005
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    Jul 29, 2012, 5:38 AM - #111

    Other projects have held this up, but I decided it was time to get back to my Jango helmet.
    First pic shows the painted helmet before the rub n' buff.

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    Then comes the masking.

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    Rub n' buffed!

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    And Pinstripes.

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    Here is a pic showing how the visor bolts in.

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    Next up the gasket skirt & weathering.
  12. SNOWAURE's Avatar
    Member Since
    Oct 2009
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    399
    Jul 29, 2012, 12:49 PM - Re: Australian Jango Progress #112

    Hi Captjono, you have done a great helmet work man!!!!!!!!!!!!!!!!!!! wonderfull piece!!!!!!!!!!!! you helmet is great man! nobody can tell you is not.......... check my work here:


    TUTORIAL CASCO A1 HELMET PEDRO NIEVES pictures by snowaure - Photobucket
  13. CaptJono's Avatar
    Member Since
    Jan 2005
    Posts
    336
    Aug 11, 2012, 6:11 AM - Re: Australian Jango Progress #113

    Took a couple pics, one outdoor showing the paint color in natural light and another showing the RF graphic reflected in the helmet's visor.
    Hope you enjoy!
    Also, today I bought the acrylic paints to start the weathering, so probably next week for that job.

    Cheers!
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  14. Member Since
    Jun 2009
    Posts
    137
    Aug 15, 2012, 1:35 AM - Re: Australian Jango Progress #114

    lookin good mate

    just wondering what colours/paints you used? I had Cruzer send me some colour samples ages back and had some paint spray cans made up but never been 100% satisfied.

    your colours look pretty close!
  15. Trout's Avatar
    Member Since
    Sep 2010
    Posts
    147
    Aug 15, 2012, 11:03 AM - Re: Australian Jango Progress #115

    I love it. How did you do the RF graphic?
  16. SEEKER's Avatar
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    Feb 2002
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    4,371
    Aug 15, 2012, 11:48 AM - Re: Australian Jango Progress #116

    Freaking awesome!!!!!
  17. CaptJono's Avatar
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    Jan 2005
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    336
    Aug 17, 2012, 9:23 PM - Re: Australian Jango Progress #117

    Hey Guys,
    Westrooper, the paints I used were sent from the US, Rust-Oleum Royal Blue & Krylon Short Cuts Ocean Blue (not available in Australia).
    Maybe someone from the US could inform you of their current availability.

    Trout, I made the RF pic in Photoshop & transferred it to old style (photochemical) slide film. You can download the pic I used from post 20 in this thread.
    Posts 11, 33 & 57 detail the RF build. If you need more specific info just let me know.

    Seeker, you sir are the hallmark of Jango builders, thanks for the great feedback.

    I believe my helmet gasket is in production, so all thats left to find is a purple balaclava. Anyone got any leads on this?
    Also, if anyone has spotted anything I might have missed (or needs adjusting) be sure to chime in.
    Weathering starts in a few days....watched Seeker's weathering video over & over, must summon courage....
  18. CaptJono's Avatar
    Member Since
    Jan 2005
    Posts
    336
    Apr 25, 2013, 9:25 PM - Re: Australian Jango Progress #118

    I have attached my Chucko helmet gasket, its a really nice piece.
    It took some time to get the installation right.
    I used a band of steel to help keep the gasket snug with the helmet.
    All I require now is a neck cover and this build will be complete.
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  19. Chucko's Avatar
    Member Since
    Sep 2008
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    482
    Apr 26, 2013, 1:41 PM - Re: Australian Jango Progress #119

    DUDE! That looks fantastic.
  20. Vultana's Avatar
    Member Since
    Mar 2012
    Posts
    520
    Apr 30, 2013, 12:13 PM - Re: Australian Jango Progress #120

    Wow, that is beautiful! I can't wait to get my Chucko gasket now!

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