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EP3 Clone pilot helmet project (Update: Completed 9/6)

  1. #1
    EVO3's Avatar
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    EP3 Clone pilot helmet project (Update: Completed 9/6)

    This is a project that i started about 3 years ago. There were a few other projects that kept putting this helmet on the back burner and although i finished the helmet quite a few months ago, i just got around to molding it. This forum seems pretty hands on when it comes to builds so i thought id post it here from beginning to end. Just pics though.......



















    Last edited by EVO3; Sep 6, 2009 at 8:15 PM.

  2. #2
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project





















    This is where the helmet project ended.

  3. #3
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project

    This is where it restarted.....















    Now some side by side pics with a TIE helmet for size comparison.........






  4. #4
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project



    And here we have the clones!



    And after hours of getting high on Bondo and spot putty, here are the fruits of my labor. You'll notice the mohawk has been fixed and it is now indented.







    A view from the top shows how the raised lips on the mohawk go back to blend into the helmet.










  5. #5
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project

    Added the triangle thingies on each side of the helmet........




















  6. #6
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project





    From here, i just plugged up the holes from the back with epoxy putty then when that dried, i came in from the top and epoxy puttied the holes. Next was the hose couplers. I fabricated the prototype from PVC pipe and some styrene strips.... a little epoxt putty as well.



    Molded that piece and made clones!!!!!



    Heres the helmet with all the front work done. Just for the record, the hose couplers will be cast separately from the helmet.









    Work on the back detail has begun as well already.


  7. #7
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project

    Back plate installed and ready for primer.....



    All primered up!







    Here is the visor installed. After it was test fitted, i pulled it out and made it into a vacuum buck so that i can make the amber lens.





    Here is the buck.


  8. #8
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project

    First coat of RTV.........


    Separating wall for the mother mold..........


    First of three parts to the mother mold.............


    Both sides done...........


    Now it'll get flipped over and the whole process will get done to the backside of the helmet.





    Success!!!

    Visor has been all cut out. Still need to do the cheek vents.









    Heres the vac buck for the amber lenses.



    This project is by no means over. I need to make copies of the visor bucks, then have them thermoformed by a friend. Then its time for a nice paint job. stay tuned for more!

  9. #9
    Replicant Shadow's Avatar
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    Re: EP3 Clone pilot helmet project

    whoa dude! I can't believe it has been 3 years, seems like yesterday. I need two closed visor helmets for my Clone AT-AT Driver project. Your work is amazing!
    Last edited by Replicant Shadow; Jul 28, 2009 at 9:14 PM.

  10. #10
    Mereel's Avatar
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    Re: EP3 Clone pilot helmet project

    Wow, that's some amazing work there my friend. Really good stuff.

  11. #11
    jedi.paramedic's Avatar
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    Re: EP3 Clone pilot helmet project

    ***. That is some serious work.

  12. #12
    clonesix's Avatar
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    Re: EP3 Clone pilot helmet project

    I know that I have seen this over the pas tfew years, but I just love the progress shots of it all from start to finish!

    That is some top-notch stuff there. What's next?

  13. #13
    I helped at SDCC '08 MandalorFett's Avatar
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    Re: EP3 Clone pilot helmet project

    Wow, awesome work!!!!!!!!!!!!!

  14. #14
    Ogait-Nas's Avatar
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    Re: EP3 Clone pilot helmet project

    I can't believe it! O.O

    Incredible man!!

    Can I ask you something? What was the crest originally made? In the 2nd, 3rd, 4th and 5th photo we can se it's a white and flexible material but... which is it?

    Thanks and congratulations!

  15. #15
    EVO3's Avatar
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    Re: EP3 Clone pilot helmet project

    Thanks guys! Yeah, now to decide on a paint job.

    Ogait-Nas said: View Post
    I can't believe it! O.O

    Incredible man!!

    Can I ask you something? What was the crest originally made? In the 2nd, 3rd, 4th and 5th photo we can se it's a white and flexible material but... which is it?

    Thanks and congratulations!
    Its plastic styrene. You can get it at most hobby stores. Its under the name "Evergreen".

  16. #16
    Wildabeast's Avatar
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    Re: EP3 Clone pilot helmet project

    ummmm......wow

  17. #17
    boba trooper's Avatar
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    Re: EP3 Clone pilot helmet project

    Dam Evo that is some nice work indeed I would love one of these helmets you going to be doing them for people let me know, and I will say again very very nice work im licking my lips just looking at it in amazment.

  18. #18
    azheat01's Avatar
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    Re: EP3 Clone pilot helmet project

    Very nice!

  19. #19
    mrbungle's Avatar
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    ALABAMA!!!!!
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    Re: EP3 Clone pilot helmet project

    that is stupid nice, evo!! i like the inset trim trick on top of the helmet. impressive ,most impressive.

  20. #20
    cdr thire's Avatar
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    Re: EP3 Clone pilot helmet project

    That's what I continue to talk about...

    Andy - you the man!!!

  21. #21

    Member Since
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    Tacoma WA.
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    Re: EP3 Clone pilot helmet project

    Fantastic work.

  22. #22
    stormtrooperguy's Avatar
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    Re: EP3 Clone pilot helmet project

    is that plastipaste for the mother mold? how do you like it? i've always used fiberglass, but i've been tempted to go for something that smells better

  23. #23
    SlaveR5's Avatar
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    Re: EP3 Clone pilot helmet project

    very good stuff there!!!

  24. #24
    boba trooper's Avatar
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    Re: EP3 Clone pilot helmet project

    Wow Evo3 that is the dogs danglies, super work and I love it are you going to be casting and selling these and also do you do other helmets as im after one or two like bacara and also ep2 clone pilot plus I would have to add one of these bad boys to my list.

    bobatrooper

  25. #25
    tc-2917's Avatar
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    Re: EP3 Clone pilot helmet project

    I have said it once and I will say it again.... *** that is freggin amazing!!! Just tell me when and how much!!!!!

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