Y-wing / A-Wing helmet ROTJ scratchbuild

Hi, here's a quick update of the box and the cross section piece of wood just before I start with a 2 piece mould in Silicone...

box-for-casting-(5).jpg

Just got to close the gaps and add the pieces to align the 2 halves. Anything else I need to do? (Nate, I'm looking your direction!)

Rich
 
rofl - oops soz mate
text me next time mate- school hols starting soon, will be spending time with kids rather than near a PC
pm sent mate
 
Hi all,
Here's another quick update of the process so far...

2nd-pour-small.jpg

GRP-jacket-2.jpg

Since these pics I've removed the wooden section and will be casting the 2nd side in RTV shortly.

Rich
 
My only concern is is that MDF board you're using for your flange?
Be extra careful it doesn't get wet and possibly warp, bro!
 
I've removed the board since these pics. It stayed nice and dry and flat.
I'll upload some other other pics in the next day or two.

Thanks!
Rich
 
Here's another couple of pics of the progress.

casting-2.jpg
H2.jpg

since this I've done more pours and it needs just 1 more later of RTV with thixo then I'll make the jacket in glass for this side.

I will be removing the plug from the moulds this week! :)

Rich
 
Hi all, at long last...(seemed like forever to me) I've got my moulds almost ready to go!

moulds-(1).jpg

moulds-(2).jpg

I removed the fibreglass mother moulds OK and the plug came out fine.

Big thanks to Nate (Heatshock) for giving me plenty of pointers as I went! Thanks dude!

I plan to go the fibreglass route and see how I go for the 1st pulls.... stay tuned rebel pilots!

Rich
 
Thanks dude! Its a good job we have the internets these days! The tutorials of Heatshocks, Evo3 and Volpin Props helped me no end!

Rich
 
Rich - was my pleasure mate, the more UK makers the better in my book ;P
mold looks excellent !!!! Very nice work mate
and dont sell yourself short mate, you obviously already knew a lot of what I was talking abt - glad I could help
good luck with your castings!

Nate
 
Hi all,
Having gelcoated and glassed the 2 sides late last week, I removed the 2 halves today from the moulds.
casting-(9).jpg
web-5.jpg

In these pics the majority of the sanding is done, just a little more to do before bonding the helmet together.

web-1.jpg
web-2.jpg
web-4.jpg

Once done it will be time to trim the front section out and starting thinking about making a former for the visor.....

Rich
 
This is really a good looking build.
Very clean.

I may have missed it, but is scale 1:1 with the screen used version?

There is a Pep version available, but seems a little small.
 
Hi, yes full size with dimensions as close as I can guestimate!
It started with a (Medium) 80's motorcycle helmet as a start point (as you can see in this picture here)

Untitled-3.jpg

Regards,
Rich
 
Last edited by a moderator:
Well I don't know how many I'm making yet (this is #1). It is a big helmet that will need padding so your head sits where it should.
It's not that its oversize and the start point was a Medium...
I'll have a measure and let you know.

Regards,
Rich
 
Here's a few more with todays progress.
trimming B.jpg

trimming C.jpg

trimming-E.jpg

Here you can get a good idea of scale compared to a Hasbro Clone Trooper lid.

Rich
 
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