I have wanted to do a Star Wars cross over to Steampunk for a few years. Boba Fett was my first choice, but I know of several people that had done it and didn’t want to rehash it. Jodo Kast was suggested akin to a dare. I had a little over a month to complete the project.
I thought that I could modify a ready-made helmet. The Ruby’s and voice changer helmets were very disappointing, so I chose to scratch build my own.
This is where the fun began. Many thanks to Wizardoflight for the amazing templates
I used a batting helmet for the dome. The sides were built utilizing a different technique than the standard bondo and fiberglass. They were constructed with plastic “For Sale” signs and craft foam sheets. I then coated the foam with several thin coats of craft glue and covered it with Smooth-On Smooth-Cast 65D. The glue provided adhesion of the “rotocast”, without damaging the foam.
It can be sanded and painted like plastic. Plastic primer is a must.
I will post more photos soon.