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  1. Cruzer's Avatar
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    Jan 5, 2009, 3:55 PM - BKBT Cold Cast Helmet Project #1

    Hey guys, just wanted to share a little side project I started working on in between resin drying for armor. I believe it is the first of it's kind as far as BKBT helmets go because of its cold cast property. I still need to paint the ears royal blue, and affix the rf ear cap, visor, and screen mesh. My painting skills pretty much suck mainly because I'm impatient (I've already had to redo the ears twice). So I'm happy if it manages to look halfway decent.

    Assembling this almost makes me want to do another Jango.

    Enjoy,
    Cruzer
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  2. TheDentedOne's Avatar
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    Jan 5, 2009, 4:33 PM - Re: BKBT Cold Cast Helmet Project #2

    Looks great to me Cruzer! Awesome cast!
  3. Jan 5, 2009, 5:34 PM - Re: BKBT Cold Cast Helmet Project #3

    YUP! The whole thing is a complete mess, better send it on over to me and I'll see what I can do with it!

    Quote Cruzer said: View Post
    Hey guys, just wanted to share a little side project I started working on in between resin drying for armor. I believe it is the first of it's kind as far as BKBT helmets go because of its cold cast property. I still need to paint the ears royal blue, and affix the rf ear cap, visor, and screen mesh. My painting skills pretty much suck mainly because I'm impatient (I've already had to redo the ears twice). So I'm happy if it manages to look halfway decent.

    Assembling this almost makes me want to do another Jango.

    Enjoy,
    Cruzer
  4. Dark-Side's Avatar
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    Jan 5, 2009, 5:56 PM - Re: BKBT Cold Cast Helmet Project #4

    A very very clean work!:thumbup Well done my californian bro!
  5. DarthMiller's Avatar
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    Jan 5, 2009, 6:28 PM - Re: BKBT Cold Cast Helmet Project #5

    WOW!!!
  6. FettOfficer's Avatar
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    Jan 5, 2009, 7:44 PM - Re: BKBT Cold Cast Helmet Project #6

    It's about time you worked on my helmet....hehe J/K
    Looks fantastic bro!
  7. Cruzer's Avatar
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    Jan 5, 2009, 9:27 PM - Re: BKBT Cold Cast Helmet Project #7

    Thanks guys, being able to skip the whole Rn'B process made the assembly process so much easier and cleaner.

    FettOfficer, do you have one yet?
    I'd considering making this one available once finished, and at a good price because my painting skills are marginal at best.
  8. I helped at SDCC '08 Jango 5204's Avatar
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    Jan 5, 2009, 9:43 PM - Re: BKBT Cold Cast Helmet Project #8

    I think the paint looks just dandy.
  9. FettOfficer's Avatar
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    Jan 5, 2009, 10:13 PM - Re: BKBT Cold Cast Helmet Project #9

    Quote Cruzer said: View Post
    Thanks guys, being able to skip the whole Rn'B process made the assembly process so much easier and cleaner.

    FettOfficer, do you have one yet?
    I'd considering making this one available once finished, and at a good price because my painting skills are marginal at best.
    I don't have a CC one...but....Of course I'm willing to take this off your hands. Will this be #1 from u?
    My painting skills are not that great as well...hehe!
    PM will be sent:
  10. Jan 6, 2009, 5:05 PM - Re: BKBT Cold Cast Helmet Project #10

    that's a great looking bucket. awesome paint job.
  11. Cruzer's Avatar
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    Jan 6, 2009, 7:23 PM - Re: BKBT Cold Cast Helmet Project #11

    Thanks guys. Got the ears painted and a shade 5 visor installed yesterday. Now to get to work on the rf.
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  12. FettOfficer's Avatar
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    Jan 6, 2009, 8:29 PM - Re: BKBT Cold Cast Helmet Project #12

    ooooooh! Nice!!!
  13. Cruzer's Avatar
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    Jan 6, 2009, 8:37 PM - Re: BKBT Cold Cast Helmet Project #13

    Quote FettOfficer said: View Post
    ooooooh! Nice!!!
    I'm thinking of installing non-working blue LEDs, instead of painted ones at the top of the rf. What do you think?
  14. FettOfficer's Avatar
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    Jan 6, 2009, 8:55 PM - Re: BKBT Cold Cast Helmet Project #14

    Quote Cruzer said: View Post
    I'm thinking of installing non-working blue LEDs, instead of painted ones at the top of the rf. What do you think?
    Go for it brotha!
  15. REDBOY3384's Avatar
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    Jan 6, 2009, 9:08 PM - Re: BKBT Cold Cast Helmet Project #15

    +1,0000

    Keep up the awesome work brother.
  16. Cruzer's Avatar
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    Jan 7, 2009, 4:31 PM - Re: BKBT Cold Cast Helmet Project #16

    I finished up the rf and connected it using a series of washers (rubber, fender, flat, locking). Only other thing I can think of doing would be taking some 0000 steel wool to the blue areas to knock down a little of the gloss. Other than that, it's done as far as I'm concerned and I'll let its new owner apply the weathering.
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  17. Jan 7, 2009, 5:07 PM - Re: BKBT Cold Cast Helmet Project #17

    Ummm, Pinstripes?

    Also, How did you install your visor on this one? Looks Good!
  18. Cruzer's Avatar
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    Jan 7, 2009, 5:25 PM - Re: BKBT Cold Cast Helmet Project #18

    Pinstripes?...this is the Pre-"Pro"pinstripe version!
    Off to the auto paint store!
  19. Member Since
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    Jan 7, 2009, 5:27 PM - Re: BKBT Cold Cast Helmet Project #19

    That's a real nice looking bucket man. I always have trouble w/ the taping off of the mandibles for painting and having the paint tear when I pull up the tape, and still haven't found a totally acceptable way to mount my visor. I end up usually mounting bolts and using wingnuts to screw down and hold the visor in place, but it's kinda ****** looking inside =p.

    What is your tape//paint order? With CC it's different because you're not RnBing at all...but?

    I usually RNB first, then tape it off after 2 days. Then, paint all the blue areas the dark blue, then wait 2 days, tape, and paint the light blue on the visor and trim around the helm, and the sides.

    Pulling the tape off the RnB gets rid of some of the shine, which I prefer over mirror finish, and like Cruzer said, 0000 steel wool on the blue cuts the shine down well.
  20. FettOfficer's Avatar
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    Jan 7, 2009, 9:59 PM - Re: BKBT Cold Cast Helmet Project #20

    Quote Cruzer said: View Post
    Pinstripes?...this is the Pre-"Pro"pinstripe version!
    Off to the auto paint store!
    Cruzer forgetting the Pinstripes? hehe! Another
    for the records..lol Nice Touch bro!
  21. Cruzer's Avatar
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    Jan 7, 2009, 11:30 PM - Re: BKBT Cold Cast Helmet Project #21

    Now that I think about it, I've never really been a big fan of the "pinstripes" because they just seem out of place.
    Now "kill stripes" on the other hand make more sense!

    I ordered some black 3/32" pinstriping tape from our local auto paint store. Should be in on Friday.

    I also took some fine steel wool to the blue painted areas. It did a great job of getting rid of all the little dust specks. Then I polished everything back out with some medium rubbing compound. I think it looks much better than the original high gloss.
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  22. Cruzer's Avatar
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    Jan 8, 2009, 1:12 AM - Re: BKBT Cold Cast Helmet Project #22

    For all of my previous helmets where I Rn'B'd, I usually gave the entire bucket a coat of Rustoleum Royal Blue to make the entire helmet surface nice and smooth. Then on top of that I would tape off and paint the Krylon Ocean Blue, and Rn'B last. I would use 1/8" plastic auto striping tape for the check/mandible areas because I think it produces a nicer and sharper paint line, then I would apply the easy release 3M blue tape to that. I would also tape off the silver cheek areas before lightly sanding and Rn'B them...that way the Rn'B stayed where it was supposed to. So basically my last step in painting a helmet was Rn'B. I think most people Rn'B first though.

    As for installing the visor. I tried something for the first time on this one and I think I like it over anything else I've ever tried. I got some 6-32 anchors, some 6-32 flat head screws, and some 6-32 acorn nuts (all found at Lowes). First I cut half the anchor stem off. I then threaded the screw through the bottom of the anchor. I put the acorn nut on the screw to where it bottomed out. I threaded the anchor to the acorn nut. I turned the anchor upside down and applied a small amount of CA glue to glue the screw in place. I then cut the excess part of the screw away and sanded smooth the bottom of the anchor on some 120 grit placed on a flat surface.............and viola! They are the perfect height for a welding visor when a flat 8-32 washer is used.

    Hope that description and the pics help.

    Quote [AK]Edge said: View Post
    That's a real nice looking bucket man. I always have trouble w/ the taping off of the mandibles for painting and having the paint tear when I pull up the tape, and still haven't found a totally acceptable way to mount my visor. I end up usually mounting bolts and using wingnuts to screw down and hold the visor in place, but it's kinda ****** looking inside =p.

    What is your tape//paint order? With CC it's different because you're not RnBing at all...but?

    I usually RNB first, then tape it off after 2 days. Then, paint all the blue areas the dark blue, then wait 2 days, tape, and paint the light blue on the visor and trim around the helm, and the sides.

    Pulling the tape off the RnB gets rid of some of the shine, which I prefer over mirror finish, and like Cruzer said, 0000 steel wool on the blue cuts the shine down well.
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  23. Nyx Mandalore's Avatar
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    Jan 8, 2009, 10:33 AM - Re: BKBT Cold Cast Helmet Project #23

    lol Curse you Californites and your time to work on this stuff.. I'm freezing to death. No painting or outside projects for me.. *stares at his unfinished helmet and gauntlets and cries*

    Hehe. That's looking awesome though Cruzer. Very cool.
  24. Member Since
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    Jan 8, 2009, 12:02 PM - Re: BKBT Cold Cast Helmet Project #24

    Thanks Cruz, I'll keep those tips in mind when I either repaint my current BKBT fiberglass, or pickup a CC one from you =p.

    And Nyx, I feel your pain...I live in Alaska...it's -20F right now, and it's been below -10 for 2 weeks straight. =(
  25. runJEDIrun's Avatar
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    Jan 8, 2009, 12:27 PM - Re: BKBT Cold Cast Helmet Project #25

    Now that is a handsome lookin helmet!

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