Pepakura clone helmet phase 2(comments welcome)

Difficult to comment without pics bro.

How old are you bro? Don't be so hard on yourself. I'm guessing this is your first attempt?

To strengthen the card build, you need to fibreglass the inside. Go to Halfords and get their "Davids" Fibreglass Repair Kit. It'll contain fibreglass tissue, fibreglass resin and the instructions to use it properly and safely. This will add the strength to the build you need before the next step.

Most people who use Pep go for Bondo. Over here in the UK it's just various brands of car body filler. THE EASY SAND type, not fibreglass compound as it's a nightmare to sand. Work in small sections and don't mix too much filler as you'll end up with alot of waste which will cost you. Take your time, don't just slap it on. Try to smooth it over like spreading butter on bread. LOL! Try to keep to the flow of the lines/contours of the pep build as you go. This will minimise the ammount of sanding you need to do to get the proper finish.

I could go on really with loads of little bits of info but it would overload you. Keep to those basics and you'll be Ok. It's all a learning experience. There are plenty of tutorials over at the 405th forums too. Also, look for T_Bone9600's Imerial Guard thread here at TDH. It's a pep build that is probably the best I've seen and shows what can be achieved with patience and dedication. AND TIME!!!

Send me a PM with your email address mate. I'll email you something that will help if you're going to start over.

Looking forward to it mate.

I have that helmet! There are a couple more free pepakura files over at clonetrooper.net if you want more options. But skip's files are top notch if you want to go with his.
Nice job so far, keep up the good work!

Looking forward to it mate.

That is sweet keep it going

I'd say it's either the weather or you didn't use quite enough hardener. Mix up another batch of resin with more hardener and give it another coat. It'll be fine.

i've never done paper craft, but i'd imagine a heavier material would work better... to hold its shape a bit more?

You're right Brian, I go for a 300gsm card. It's plenty workable and gives s good base to work from.

thks for the advice mates.Just bought more resin and hardener,as the fibre kit only gives a small amount of resin.

progress soo far,with a layer of bondo.

Not bad mate. I'd have built the helmet with the visor in to help the face keep its shape but it doesn't look bad. Work in sections like you've started and you should be fine. get sanding!!!!! LOL!

thanks alot mate.

current progree today.Problem with the dome area.Sprayed primer and gloss white to see how it would look.

nd help lads..the paint does not have the plasticy paint i want?why?
comment plz!!

Everything Tim said above is right. I'll also add that patience is key when working on a helmet. It doesnt happen overnight or even in a few days. It takes weeks. You work on it, one section at a time making sure that everything is as symmetrical as you can get it. I think you jumped the gun when you painted it white. What you need to do is get yourself a good fast drying filler primmer and that will show you areas that need fixing.

Remember, patience is key. Take it slow.

They're right bro.

My Mando lid(for my custom) is probably one of the more straght forward lids to scratchbuild and that took a about two months all in to get the way I wanted it.

The key is indeed patience and also perseverance(sp?). It's easy to get frustrated particularly with your first build as there's a long period where you feel like you're getting nowhere. It can be hard to keep going when you're getting fed up of sanding but then before you know it, you get some primer on it and you can see just how much progress you've made.

Keep at it.

Man, what a mouthfull of advice.Really appriciate this guys,thanks.

Nothing worth doing, ever comes easy.

bondo seems preety expensize at a low amount...any1 no any cheap large bondo uk

Haldfords. U-POL EasySand. I think it's around 17.99 and you get a big tin. I managed to do some armor and two helmets with it.

mine was a small tiny can which didn't last be half a helmet.Thks for the advice mate

Originally Posted by Trooper937

mine was a small tiny can which didn't last be half a helmet.Thks for the advice mate

the small cans are way overpriced.

in us terms, i pay $12 for the quart cans and $25 for a gallon.

That's crazy! I don't think it's that bad here but the smaller cans are overpriced.

wow! nice work!

'nice work'??-thats a first.Thanks alot mate .$12.00 dollars ,so thats 6.00 quid.Thats preety cheap.Isn't there any bondo for a cheap price,cause imagine you owned a garage and was fixing up a car with dents (its a good car),and buying bondo for its body,it would cost you the world.There must be a cheap supplier somewhere.

Originally Posted by Trooper937

'nice work'??-thats a first.Thanks alot mate .$12.00 dollars ,so thats 6.00 quid.Thats preety cheap.Isn't there any bondo for a cheap price,cause imagine you owned a garage and was fixing up a car with dents (its a good car),and buying bondo for its body,it would cost you the world.There must be a cheap supplier somewhere.

If you are fixing up a car, spending 20 - 30 pounds on it isn't a big deal I'd think.

I probably spent about $150 US on the materials to make my animated clone helmet, then another $200 US on the mold.

Is that all you spent Brian? That lid has gone through so many changes I'd have thought the original cost you well over $500 to make?

Yeah, building your own is not cheap bro. In fact, I'd say it can be cheaper to be one ready made in some cases.

stormtrooper guy,was your helmet a conversion or a scratch-build?I didn't know moulding costed that much?

Originally Posted by Skupilkinson

Is that all you spent Brian? That lid has gone through so many changes I'd have thought the original cost you well over $500 to make?

Yeah, building your own is not cheap bro. In fact, I'd say it can be cheaper to be one ready made in some cases.

hahaha... that's the cost per version.

That makes more sense.

Originally Posted by Trooper937

stormtrooper guy,was your helmet a conversion or a scratch-build?I didn't know moulding costed that much?

both.

i started with a hasbro. filled the seams, fixed the visor, and made a mold of it.

then i took one of the castings and made a closer-to-accurate attack of the clones helmet out of that.

another casting was made into toon v1. i then reshaped the toon v1 and made the toon v2. the toon v2 was further refined into the toon v3.

overall, from the day i bought that first hasbro i've sunken probably a couple thousand into the project.

silicone is very expensive. it's around $180 US for the stuff i use, then another $25 or so for the material to make the mold jacket.

that makes sense,but what do the guys who sell armour on ebay use to make copies,silicon?

Have hand-sanded the bottom section(near the mouth) to try and see if all you guys were right.The answer was Yes.patience.The area is starting to appear shinier.But if i wanted a copy of it,i would have to make my own mould?

Just a size comparason for my first attempt which didn't go very well to skips brilliant one.Thanks again .The design on the smaller one was a test run for commander fox,one of my fav clones.The paint was only watercolour as it washes away easily.

Originally Posted by Trooper937

that makes sense,but what do the guys who sell armour on ebay use to make copies,silicon?

armor and helmets are usually different.

helmets you usually make a silicone mold then produce the helmets out of some sort of resin.

armor is usually vacuum formed plastic, pulled over a positive that you make out of something durable (plaster, wood, etc...)

in addition to the numbers above, there's a cost for resin too... around 20 - 25 US a helmet.

it's a LOT cheaper to buy a helmet than scratch build / mold / cast. the latter only makes sense when you plan to make a bunch of helmets.

Yeah, or if you want a helmet that is hard to find or unavailable.

Do you guys thik i should continue with the build or just save some coins and get an efx helmet.But are there any shops,sellers that sell their casted helmet.I was almost excited when i found star fotress,but now distrust them from comments.By the way,why don't everyone vacuum form their helmet?(sorry abt asking too much questions).Ayway,back to the main topic,should i continue,or is it to sh~~ to continue

You can't vacuum form clone helmets. vacuum forming doesn't grab hard angles, to do that you need to cast a liquid into a negative mould. There are a few people that sell copies of clone helmets. They usually start at around the 200 usd mark. If all you want is a clone helmet, just buy one and paint it. If you're interested in learning to make things, stick at it but bare in mind it can take years to learn. I've been messing around sculpting things for around 8 years, before my sculptures started looking right, I had a lot that looked aweful (not that there isn't still a lot of room for improvement)

you don't really vac clone helmets because you can't get the same level of detail as you can with silicone. plus, you can make it all in 1 piece, rather than several. i've seen some vac formed clone helmets and they all have looked a bit marshmallowy.

stormtroopers / tie / at-at and the like are vac formed in pieces, just like the originals. but they have softer features than the clones anyway.

as for whether it's worth doing... that's up to you. are you having fun? if so, keep at it.

NZ's right bro. Sounds like you're alowing yourself to be defeated? Or put off by the cost maybe?

I get tempted to buy helmets, sometimes I do but I really get a buzz out of seeing something I created take shape. Then to be able to wear it and show it off after the hard work is done? Priceless!

But going back to what NZ said, it can indeed take years to become confident in your abilities and to build up the knowledge required. I still consider myself a newbie at building,sculpting and moulding and casting. I'm constantly learning new tricks and sometimes discovering a few by myself.

I can understand the financial reasons for wanting to jack it in but don't be put off by the challenge.

Alright,i understand mates.To buy a helmet is for people who want a helmet,but to make a helmet is for people who enjoy the helmet and have a passion.I think i will do both now,u lot has inspired me

more pics will come soon lads.

WOW!!:thumbupFor a rookie thats amazingly good.To tell you the truth bro,it embarasingly high-level.I'm also new here, as i chill around clone-empire.net Wish i was that good .I'm more on phase 2 side, but phase 1 is nice.

sounds like u are getting all the right advice mate

build the helmet - its great fun. just dont think you will find it cheaper. aside from all the material cost already mentioned; also think abt the amount of YOUR own time put into it. Not only in terms of paid time, but time spent away from parents, children, girlfriends, wives, friends etc

in terms of buying a lid - there are good fan sculpts that are cheaper than the eFx (*sideways glance at stormtrooper guy*). most are US based - drop me a pm if u are interested in some info.

the bay has its uses, but for a newbie - its often a minefield, lots of cheap knock-offs on the bay, and also the steal from our true artisans (recasting is BAD!). you've already taken the correct 1st step by coming on here and doing some of your basic research.

Some advice, get yourself a mouse sander and a pack of sand papers at Walmart. Costs around 30-40 bucks (USD) and will save you a LOT of work on the sanding.

Also, how old are you??? I'm thirteen, and this is PRETTY dang good.

You gotta keep workin on your clone helmet. I have so far made 2 mando buckets, and I haven't even dreamed of attempting something as daunting as a clone bucket, and seeing your work progress, I think I can do it. I'll be pm'ing skip soon

No, there are a LOT of younglings here, but I am one of the many 30 somethings here.
I think they ask, because you seem to be so down on your self when you dont need to be.

I asked as I detected a hint of youth there. LOL! Also because the younger you are then generally the more limited you are for use of products/chemicals too. My daddy would never have let me use resin or body filler at the age of 16. Good thing I'm 30 now and can do whatever I want!!!!!!!

True skip, the same applies when i try buying primer and gloss paint, suspecion is raised and i'm questioned as they think i'll do grafity.

Lol, i've found a 150 watt sander(using my own cash, so cheaper the better)...is that good?

Yeah, that'll do it mate. Though because of the ammount of dust you'll kick up keep it clean as you can and wear dust masks as filler dust is nasty stuff to breath in.

Thank alot.Was wondering how you make your 3d models, so i gave it a try. 5 mins later, gave up.You must really know your software.

thks again mate.

Yeah it takes a while to pick up.

Also, buy cheap sanders mate as the fine dust when you sand ruins sanders after time so you'll always need to replace it eventually. Unless you have a pressure air hose for blowing the dust out?

Originally Posted by Trooper937

Answer to fractal's question, I'm sixteen.Thks for more advice lads really helps. I will eventually purchase a mouse sander,
by the way,
why does everyone asks about my age, it does cause suspecion.

Just wondering, the way you were a little unsure of what you made is EXACTLY how I felt when I failed* on my cardboard Bucket.

*Note, read: thought I failed.

I get weird looks when I go to home depot and buy 6 cans of spraypaint, a gallon of fiberglass resin, cans of bondo extra hardener, miscellaneous electrical parts (spark plug kind of things) and a length of wire.

I wonder why?......... :P

Aha, I'm 15, looking to start on a project (need to decide which one to dedicate myself too first!). Just thought I'd give you a big for this, it's hard to do things like this at our ages (especially when most people our ages apparently have slightly more... exciting uses for the materials used... so I guess they're frying their brains as we actually use ours).

Keep it up!

Hikarikuen, I might suggest starting with what this web forum is all about... THE FETT

get the WOF templates and some card stock and give it a try, it is much easier than the clone helmet.

Dont be afraid to ask us questions, and really dont forget to start a WIP so we can see how you're doin'.

I thought i was among 20+ people, nice to have mates my age.Hi to you guys.Thaks alot for the posts.Would really like it if you lot continue to reply.I've struck some gold at car-boot sale having found two big cans of bondo for £3. Brilliant. Still hand-sanding till i find tim to get sander.I have a slight problem.I'll show you guys with pics.

..by the way,what does WIP mean?

Thks alot Hikarikuen.Really appreciate.(Another dump question)= whats WOF template?

WIP is Work In Progress.

WOF Is Wizard Of Flight. Wizardofflight is a member here who makes great templates for Fett gear.

HAHAHA!- thanks aLOT Skip, still new here

Here is my progress with a new coat of bondo ready for the sander i will buy.

Heres the back-view of the helmet.Notice the back section of the helmet, the button bit is facing a sideway position.Needs re-constructing.Looks real ugly at the moment.Hope i will change when im done.

WOW that's good for a first timer. NO make that GREAT.

oh man - I remember that stage in quite a few builds
sand sand sand and sand
just remember that abt 80% of what you slap on eventually ends up on the floor. in your shoes. hair. clothes.

out doors is better - but hey; where-ever you can find a space mate
as already mentioned; pls tell me you got a good facemask/respirator? bondo dust is NOT good for you!!

good luck

Originally Posted by Heatshock

oh man - I remember that stage in quite a few builds
sand sand sand and sand
just remember that abt 80% of what you slap on eventually ends up on the floor. in your shoes. hair. clothes.

out doors is better - but hey; where-ever you can find a space mate
as already mentioned; pls tell me you got a good facemask/respirator? bondo dust is NOT good for you!!

good luck

AT ALL!!!!!

Also, when I was trying to build my ep 2, I left that piece till the end, and I was just going to salvage something from home that was the correct size and shape.

I've decided to finish off this helmet, then fibreglass the outside and the cut it in the middle of the fibreglass layer which will be my new helmet.Is that right?

Fiberglassing the outside will mean A LOT more bondo works and sanding, I will give the outside a rough, unfinished look, what you might want to do is take a mold of it when you have it all smooth, here is a link to a way of doing it simply.


http://www.thedentedhelmet.com/showt...silicone+caulk

Then just cast it in plaster or fiberglass resin or anything else

Mate, i was saying that maybe i could use the helmet i have now as a mother mold and cast on it, usng fibreglass, and then take the fibreglass off,which follows the shape of the helmet.

What i was saying was, maybe i could use the helmet as a mother mold and cast it using fibreglass,which i would then peal off and work on.

wAIT.....Why did he also use expanding foam...??

the expanding foam is the mother mold, it is there to hold the silicone in shape otherwise it would just flop around.

Sorry about late progress.Its been a bad week , but have already bought a 180W sander but ran out of ammo.Now, im going to north wales,,,,.Progres and pics will come soon.

[QUOTE=Trooper937;447990]Sorry about late progress.Its been a bad week , but have already bought a 180W sander but ran out of ammo.Progres and pics will come soon.

Fiberglass resin is one of the most powerful adhesives known to man, it would not come off of the bucket without destroying your current one.

Ok, so its best to stick to sillicone and catylst molding. I've found this on ebay, will it be good enought,its a Silicone RTV Rubber Mold Making Compound - 1 Qt. Kit ...

Id say, before you go thinking of molding the helmet, you need to get further along on it. Youre looking way to far ahead. Concentrate on what you have in front of you now and when thats done, move on to the next step. Sculpting helmets and making molds, although related, are two totally different art forms. Baby steps, my friend.

Also, 1 qt of silicone will not be enough. I usually use about 2/3 of a two gallon kit on most of my helmets.

Took me several restarts before I got my work entirely right, I agree with Evo3, make sure you have your helmet as best as it can possibly be before even considering the molding stage.

I would also put some card behind the visor section, though it is really tempting to cut it out and wear it, in the end it doubles the work for molding. It will also support the front where you've had problems with cracking.

I have nearly finished my build, plus i have considered doing molding as i have said in my last posts that the helmet( nearly done) is a tight fit on my head, therefore forcing me to mold it. If it wasn't for the tight fit, molding it would be out of the question.

hey dunnoifyou saw this, but heres a link toa threadofmy Fett helmetbuild,which istarted with cardstock..theres kidof a step by step picture seriesonthere,in caseu wantto see howi did it.
http://www.thedentedhelmet.com/f23/dvh-fett-bucket-scratch-build-31411/

when you are ready to mold,you can used rebound 25, from smooth-on its less expensive and easy to use. there is a wealth of info about it on the smooth-on website, i belive they have videos of how to do that as well. But like EVO said, dont jump to far ahead of yourself!

Originally Posted by Trooper937

I have nearly finished my build, plus i have considered doing molding as i have said in my last posts that the helmet( nearly done) is a tight fit on my head, therefore forcing me to mold it. If it wasn't for the tight fit, molding it would be out of the question.

have you looked into how expensive molding a helmet is?

i usually spend around $200 usd on molding a bucket.