Hasbro Clone Helmet Conversion

looking good. i like what you did with the chin... i'll have to remember that on my aotc style buildup

Yeah the chin was the area I always knew would cause me pain, the shape of these helmets is great but the chin did stick out quite far, obviously they are meant to be the cartoony style clone wars helmets, what I did after cutting the chin out was remove about 3mm of material from each side of the chin and then put it back but from the 'inside' so it sits where it did before, albeit recessed, I had planned to then build it up with filer but decided to make a small template pictured below and then epoxy a styrene copy to the chin, luckily it worked out great so now I only have to fill in the joins

whow!!! this IS amazing!!! I' m stunned!!

You' ve done an amazing job on making this thing better then alot of clone helmets I' ve seen so far...

same wondering here about why this shouldn' t be excepted as 501st material... has it got something to do with this being an officially licensed prop then?

The new chin takes shape, here I have added filler to the outer section of the chin and I am now blending it into a nice contour

90% there with the shape of the chin, gave it a shot of primer to show the problem areas, I will be sharpening up the lines but overall I am pleased with the result of my surgery

Ok, you've come a long way baby, here she sits, on my head I have very quickly drawn in the visor to give a better overall image but this is how the helmet stands now, all that really remains is to build up the neck area and finish a few details like the circle sections on the ear for example, I have already added my card template around the neck which I am currently building up with yet more filler (hooray) I anticipate that within the next week or so I will be signing off on this project and looking into getting a copy or 2 made, anyway, pics

Awsome!

Sweeeeet!
The front section looks tons better...
Qn - at the top of each ear, there is a small gap at the front where the brow meets the ear? are you going to fill that as (if you make copies) the silicone will seep into it.

Ah yeah, there are about 6 million tiny holes to plug before this baby hits silicone!

I thought you'd have it covered...

I take it, as youre going to use it as a master for a mold. That you are going to sell some of these?

At some stage I might consider making a few copies, this is mainly for me at the moment, I wanted an AOTC clone helmet, I couldn't afford to pay top dollar for one of the decent replicas so I made this in an attempt to fashion my own, I speak of making a mold as this thing is heavy as heck with all the filer in it and I could never wear it as a costume helmet

Hmmm not the most attractive of photos but this is just to add to the documentation of this build up, here I added a ring of cardboard pieces to the lower neck area of the helmet, small tabs if you like that pointed inwards, then covered it with filler and now I am adding more to make the neck a closer fit, I do obviously need to be able to get my modest sized head in there after all, once this is done I will put more card in this time facing downwards to en-circle the neck, make sense??

I am completely in love with this thread. Too good. Really.
*applauds*

Hey thank you! I can't believe I let this helmet sit on a shelf for so long! Nearly done, I will 'almost' be sorry to finish it....almost

Mines still sitting with the same unsanded filler on it since a few months ago......

Looking awesome!

Originally Posted by HeadlessHunter

Hey thank you! I can't believe I let this helmet sit on a shelf for so long! Nearly done, I will 'almost' be sorry to finish it....almost

Well, you have had other things on your mind bruv...
Besides you'll have your hands full again soon.

I'd take a copy off ya deffo!

Trouble is I've dug myself an enormous clone shaped hole as I don't actually have any clone armour, so I am going to have to knock a wall through so I have a bit more space for the full works Yes Gav I will be a busy boy soon, and if I ever see a can of Isopon p38 again I think I might disappear up the nearest tree

getting there slowly but surely, its a good fit now getting this on my head so I wont go in any further or there will be no point! From now I will build the neck down to circle the neck nicely

ahhhhhhhhh dont stop now more pics that is looking awesome cant wait to see the finished product

Ok, with 2 layers of filer and one quick shot of primer the neck ring is starting to look half decent, a lot of spots to fill and a nice smooth finish are my next tasks

Originally Posted by HeadlessHunter

...a lot of spots to fill and a nice smooth finish are my next tasks

I know that feeling! That "smooth finish" is something that I'm not excited about

Hmmm I am 'very' excited about it to be honest......

I'm doing one of these coversions and I'm curious what diameter circle did you go with on the ears?
I'd like to leave the original caps in the ears to snap in and out for potential attachments, But I think they need to be smaller.

The 'actual' clones have smaller circles on the ear sections as shown in the picture below, I will be leaving a hole of 16mm diameter on my helmet, I have a resin 'bush' which will go in the hole and then I will use filler to blend it in

Thanks!! I'll try 16mm
Are you going to be filling in the sides of the fin so its smooth?

Extremely informative and entertaining. Great photos. I want to try this myself now!

I will be grinding off the 'lip' of the fin and then blending it in yeah

Why didn't I think of that, I filled mine in with bondo

yeah I was planning on doing that, but

a) I am short on Filler and am not buying any more, I swear the guy in the shop must think I'm building some sort of tank from filler
b) If I use more filler the helmet will be so heavy I wont be able to lift it to sand it anymore

I did my own conversion, too. Mind you, it's not as good as this one. In fact, it suck by comparison. I look at that thing every day and have to resist the urge to rip it apart and start over, especially since I have so many projects going on right now as it is. But I will probably get back to it after the first of the year.

What are your measurements for the visor opening? I know mine didn't come out right, so if you would be so kind, would you let us in on your secret.

We promise not to tell...

David.

I haven't actually finished the visor area yet but I would be happy to provide measurements once I am done

WOW dude! I'm new to THIS forum, but I just gotta say AMAZING! Completely AMAZING! I love doing these kind of projects. Take something apart and make it BETTER!! I, however, as hard as I may try probably couldn't get as detailed. Did I mention how AMAZING a job you're doing?
Uber Great dude. Keep the inspiration coming!

That looks amazing! I'm gonna get me a Hasbro and go to work!

This is a really cool project - any updates HH?

Cheers

Jez

Yes I do need to get up of my lazy backside and finish this once and for all, ok now where did I put that sandpaper....watch this space...

Friend of mine modified a hasbro helmet, looks great, i'll see if I can snag a few pic's of it.

Few small updates, an often overlooked detail is that the corners of the clones visors are curved, I am currently working on getting that curve right, also the overall shape of the visor area, I've also cut out the 'teeth' as I had to cut through them when I rebuilt the chin, I have since begun work on making a new set of 'dentures' for our clone

... not long!

So how many hours do you estimate you've spent working so far?

Thanks for showing how you extended the neck. That's the one thing that's frustrated me from trying to take on this same project.

Umm its hard to say how many hours exactly I've spent on it, I keep picking it up one day and putting it down another, its not the easiest of projects and you definitely need a certain degree of patience Yeah the neck extension was conjured up over a few days, I wanted it to be long enough so it can eventually be trimmed back if I ever get it finished and cast

Wow. It is incredible to see this helmet transform from a laughable kid's toy into a serious clone helmet! Great work!

This is great work there! I am watching this tread with great interest. Thanks for sharing your wip's.

Ok slow out of the gates I know. But this has made me want to start this project. Am I a masochist or what? No really it looks like fun. Already ordered the helmet.

Come on posty where are you?

Very Nice! I love watching these progress threads.

Great work, any new progress?

That looks awesome!

Just a small question about the Hasbro helmet. What kind of plastic is it made of? I'm hoping it's styrene or ABS. Anybody have any info? I'm going to modify mine with styrene sheet, so I was wondering what kind of glue to use. I'll probably just do a quick one for now. Thanks!

Holy Flark! That's amazing!

I was wondering, how did you get the electronics out of the little hole in the beginnig? Did you just cut the wire and not care about it?

Originally Posted by Bhush

Just a small question about the Hasbro helmet. What kind of plastic is it made of? I'm hoping it's styrene or ABS. Anybody have any info? I'm going to modify mine with styrene sheet, so I was wondering what kind of glue to use. I'll probably just do a quick one for now. Thanks!

I'd guess HDPE.... paint doesn't stick to it well, nor does Bondo. It doesn't sand well... it tends to chew up. Basically it's a very soft, almost oily material.

A great project, I enjoy seeing shelf-purchased objects modded to perfection!

Originally Posted by Octagon

A great project, I enjoy seeing shelf-purchased objects modded to perfection!

I totally agree! It's definitely easier than having to build from scratch, but it's not easy at all!

Great job! So, I'm still wondering what kind of glue will stick to this helmet. I tried super glue on mine, and my sheet of styrene is coming off already. I'm backing it up with epoxy putty, and that's not sticking either! Any suggestions? Thanks!

For mine, I used plastic epoxy to glue things together, held in place while it cured overnight. I reinforced the seams with E-6000, and used plumbing epoxy (which sets up like concrete) to back off the vents and reinforce some of the other joins. Important thing is to sand down that shine. I did a lot of work with 220-grit sandpaper to give the adhesives, putties, and paint something to bite into.

[ETA: My WIP thread can be found at CTdotN, cross-posted to Mando Mercs -- and formerly C-E.]

--Jonah

i used hot glue, but i only cared that it stick long enough and well enough to make my mold. i don't imagine that would have held up for long.

Mate just to say Well done,

I have just got my helmet and am just about to mod mine, But I am going to keep the chin as i'm looking for the cartoon trooper look

Amazing!, Great work. I too have the Hasbro Clone...and wanted to know if you have templates to fix the eyes?? or a pattern to copy?? to begin remodeling . Wait for more progress .

Saludos!

HeadlessHunter? I have AutoCAD templates I made for closing in the visor opening if you don't. This is your mod thread, though, so I won't post 'em unless you want me to.

--Jonah

What did the finished product look like?