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  1. Member Since
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    Jan 30, 2016, 6:07 PM - Stormtrooper Helmet Build - Quest for Chrome #1

    Hello Galaxy,

    I am brand new to the site and am glad to have found it! I saw a post of a friend of mine making a Starlord mask (Guardians of the Galaxy) out of cardboard, and that inspired me to make something of my own. Obviously I turned to Star Wars, my first love, and wanted a Stormtrooper helmet. Looked at a few prop-making forums, found a Pepakura file, got a bunch of supplies, laid out a giant piece of cardboard on the garage floor and got started! For this first one I am not looking to make it into an authentic looking movie prop, but more of a display piece that wont necessarily be worn. Lenses will be painted over and I want a chrome finish.

    Here we go!

    Started with cutting all the pieces and adding them together to get a general shape. Good thing I had Netflix nearby cause this part took quite a while.

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    Nacelles attached and the basic shape is ready to go. I will create the earpieces and some of the other accessories after most of the Bondo-work is done.
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    Last edited by themrdaniel; Jan 31, 2016 at 2:46 PM.
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  3. Member Since
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    Jan 30, 2016, 6:14 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #2

    Now that it is all put together, I went ahead an added Fiberglasses resin and a few layers of fiberglass cloth to the interior of the helmet. I made sure to make sure the edges around the neck were nice and thick since that is the area to be handled most. Don't want cracking!

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  4. Member Since
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    Jan 30, 2016, 6:20 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #3

    Well.... I just gave myself WAY more work than I needed with this new-guy mistake. Since it was my first time with Bondo, I overdid it and caked it on. Now I need to use a dremmel tool to remove excess fiberglass as well as a sanding block to bring the Bondo down.
    **shudder**


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    Jan 30, 2016, 6:25 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #4

    All sanded down to the paper edges.




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    Last edited by themrdaniel; Jan 31, 2016 at 2:48 PM.
  6. Member Since
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    Jan 30, 2016, 6:29 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #5

    Added an additional layer and sanded it down a bit. The rounded shape is beginning to take its form. I know the teeth and some of the accessories will take a lot of time to sharpen up.


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    Jan 30, 2016, 6:33 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #6

    Went and covered the entire helm in glazing putty (yes, not the most frugal approach, but im learning.) I wanted to fill in the low spots and pin hole cracks.

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    Even though the low spots are generally filled, I sanded down a bit too far. I still see some fiberglass poking through.

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    Jan 30, 2016, 6:55 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #7

    Covered it with a layer of sandable primer. Made it much easier to locate flat spots that will need to be fixed up down the road.


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    - - - Updated - - -

    Taped it up to get make a layer of Bondo for the headband and chin-piece.




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    Unfortunately, I forgot to take any pictures about the process of making the ear pieces and chin piece.


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  9. Member Since
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    Jan 30, 2016, 6:59 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #8

    Added some additional glazing putty and sanded things down. The overall shape is finally starting to get where I want it.


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  10. Member Since
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    Jan 30, 2016, 7:04 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #9

    Added some more quality primer to the helmet. At this stage I was also washing it over with water to see how light reflects over it. Saw lots of spots where it will need to be rounded.

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  11. Member Since
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    Jan 30, 2016, 7:11 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #10

    I got some flexible, but durable, plastic for the lenses and attached it to the interior of the helmet with some JB weld. Also added more Bondo to give it some shape.Also added more glazing putty over the helmet to make things very smooth and rounded.


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    Last edited by themrdaniel; Jan 30, 2016 at 8:23 PM.
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    Jan 30, 2016, 7:17 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #11

    Added some more primer and will do some last minute fixes before adding some high gloss white paint.

    *note: the accessories inside the nacelles will be added later on. I want to make a silicon mold of the helmet so that I can make additional helmets quicker. Adding the pieces after will make it easier.

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    Last edited by themrdaniel; Jan 30, 2016 at 8:23 PM.
  13. Member Since
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    Jan 30, 2016, 7:21 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #12

    Sorry for the low quality pics. Ill make sure to get some good ones for when this is all completed. The high gloss paint is all applied and I need to get the Chrome paint added. We will see how it goes.

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  14. Jan 30, 2016, 8:04 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #13

    awesome sauce
  15. Kokuma's Avatar
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    Jan 31, 2016, 5:59 AM - Re: Stormtrooper Helmet Build - Quest for Chrome #14

    is this your first attempt at making a helmet? either way its amazing work
  16. Tottofagrin's Avatar
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    Jan 31, 2016, 6:34 AM - Re: Stormtrooper Helmet Build - Quest for Chrome #15

    Wow, amazing build. Subscribing.

    /Kalle
  17. Member Since
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    Jan 31, 2016, 2:31 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #16

    Quote Kokuma said: View Post
    is this your first attempt at making a helmet? either way its amazing work
    Thanks. Yes it is my first time. I know more about woodworking but I have always wanted to get into some prop-building a bit. Definitely has taken a lot of time, and mistakes, to learn some things on this build.
  18. Member Since
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    Jan 31, 2016, 5:28 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #17

    WELL! The chroming solution I used isn't great and leaves things foggy looking. I will either look for a new chrome option or go paint it up in a more classic movie style.
  19. Selkaz's Avatar
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    Feb 2, 2016, 4:24 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #18

    Looks great!
  20. Member Since
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    Feb 5, 2016, 12:51 AM - Re: Stormtrooper Helmet Build - Quest for Chrome #19

    I have some work to do with some of the details that were missed. Such as subtle neck band, and some work on the chin.

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  21. Member Since
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    Feb 5, 2016, 12:55 AM - Re: Stormtrooper Helmet Build - Quest for Chrome #20

    Got some casting materials brought in to cast copies soon.


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  22. Feb 6, 2016, 3:52 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #21

    Quote themrdaniel said: View Post
    Got some casting materials brought in to cast copies soon.


    cool, i'd love a kit whenever you get them ready! looking really good!
  23. Member Since
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    Feb 13, 2016, 2:43 AM - Re: Stormtrooper Helmet Build - Quest for Chrome #22

    Did a couple castings tonight with my helmet mold. Ill use a couple for my own customized stormtrooper helmets, and will put some TLC into the castings to sell to those who would want one. They aren't ready yet though. My silicone mold on one portion of the back was quite thin and resulted in a small uneven patch that will be needing touch ups to make it a more quality resin kit.

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  24. Member Since
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    Feb 13, 2016, 1:30 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #23

    Here is a link to buy a Resin Pull if anybody is interested.

    White Stormtrooper Resin KIT 1 1 AND Wearable | eBay
  25. Member Since
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    Feb 17, 2016, 4:28 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #24

    Have this particular pull all putty'd and primed. I will be getting this one hydrodipped right away to see how the film looks with the helmet shape.

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  26. Member Since
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    Feb 26, 2016, 6:10 PM - Re: Stormtrooper Helmet Build - Quest for Chrome #25

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    Dipped one of my helmets today. Turned out pretty decently. Not I can paint the lenses, headband, cheeks, and chin pieces black, or a color to bring them out. I am also considering splitting the helmet in half down the center to paint one side a solid color, or just original white. Then it will be a half half.

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