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  1. RalfSkunk's Avatar
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    Jul 14, 2014, 2:39 AM - Building Armor for Star Wars Celebration 2015 #1

    I'm new to the Dented Helmet, but I figured it was time to start posting some stuff. My wonderful wife has agreed to going to Star Wars Celebration with me next year (it really didn't take too much to talk her into this) and our goal is to have a set of his and hers Death Watch armor. While this is not a huge undertaking when you figure we have eight months to get everything ready. I've decided to build everything from scratch. The good thing is, I've built some costumes before and have some great friends to help.

    This being said, here are my progress pictures from Day 1:

    f58689085137719c6c65915f3a4614ec-jpga2e59169b2b46925568c20113e51d55f-jpg59b225deb3ed6e917d0ae1f8f2c2e51c-jpg1c6b7f4f10da6188eef19e51f94ebd67-jpg35e2dcbefe733b3278e74722b39b6e54-jpg
    I figured a kid's bicycle helmet would work for the dome. Im not sure if anyone else has tried this.

    I was feeling pretty good about my progress, but my friend Shawn said we should take a picture of my helmet with a few of the helmets he's working:

    7e9b96232cfb32c4da817f87143e2e10-jpg

    But then he said he needed to add a few more helmets:

    4e2ca847ac999df97bf210d6a745b72c-jpg

    ... but then apparently he was still missing a few:

    32833aa7adcc5e6717e0ac4994e1d611-jpg

    I think my helmet's still in this picture...
    Last edited by RalfSkunk; Jul 18, 2014 at 12:02 AM.
  2. Syper's Avatar
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    Jul 14, 2014, 9:11 AM - Re: Death Watch Armor for Star Wars Celebration 2015 #2

    Nice Work Brother! I’m always amazed by scratch builds.
  3. RalfSkunk's Avatar
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    Jul 16, 2014, 1:58 AM - Re: Death Watch Armor for Star Wars Celebration 2015 #3

    I was able to get a little more work done today. (That day job thing keeps getting in the way of this.)
    Today's progress pictures:

    photo-2-1-jpg
    Sanded some more of the Bondo down.

    photo-1-2-jpg
    Started on the slots for the back of the helmet.

    photo3-jpg
    Still working on the slots. (These will take longer than the rest of the helmet.)

    photo-3-4-jpg
    Got the slots done, time to call it a night.

    Only 274 days to go... might even get this one done in time.
  4. RalfSkunk's Avatar
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    Jul 18, 2014, 12:05 AM - Re: Death Watch Armor for Star Wars Celebration 2015 #4

    Syper said: View Post
    Nice Work Brother! Im always amazed by scratch builds.
    Thanks - I know I'll be more satisfied when it's done, but I can't wait until I start painting this thing.
  5. RalfSkunk's Avatar
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    Jul 18, 2014, 12:22 AM - Re: Building Armor for Star Wars Celebration 2015 #5

    Got a few more hours done on the project. Can't wait for the weekend so I can get something done. I think I'm going to 3D print the ear pieces. Every time I look at them, it just seem too easy not to.

    Day Three Photos:

    day-three-1-4-jpg
    Got the slot thingamabobs put in place.

    day-three-3-4-jpg
    The helmet is really starting to come together.

    day-three-4-4-jpg
    My friend Shawn test fitting the helmet.
  6. Member Since
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    Jul 18, 2014, 9:29 AM - Re: Building Armor for Star Wars Celebration 2015 #6

    Great job with the helmet. I am looking forward to seeing the rest of the build.
  7. thorssoli's Avatar
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    Jul 19, 2014, 1:59 PM - Re: Building Armor for Star Wars Celebration 2015 #7

    Me too.
  8. RalfSkunk's Avatar
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    Jul 20, 2014, 12:04 AM - Re: Building Armor for Star Wars Celebration 2015 #8

    I'm not sure why, but I felt this build needed something digital in it. While I assume that I could have found all kinds of 3D files on the internet (it's a magical pace) but I thought it better to dust off my computer and polish up my modeling skills. It may be worth mentioning that the last time I did any 3D modeling was with AutoCAD Release 10... Needless to say, it took a bit longer than it should have. Regardless of the journey, I was pleased with the results:

    Day Four Pictures:

    day-four-1-2-jpgday-four-2-2-jpg


    I got an early start this morning and met up with my friend Shawn. He tinkers in his makeshift workshop from time to time (more like 12 to 16 hours every day) and happens to have a CNC machine that made up my parts.

    Day Five Pictures:

    day-five-1-9-jpgday-five-2-9-jpgday-five-3-9-jpgday-five-4-9-jpgday-five-5-9-jpgday-five-6-9-jpgday-five-7-9-jpgday-five-8-9-jpgday-five-9-9-jpg
    Last edited by RalfSkunk; Jul 20, 2014 at 2:06 AM.
  9. RalfSkunk's Avatar
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    Jul 21, 2014, 12:28 AM - Re: Building Armor for Star Wars Celebration 2015 #9

    I found a bit more time today to continue work on the helmet. The ear pieces that I cut out yesterday were too small, so my friend Shawn cut some more out this morning. I got these sanded down a bit and sprayed more primer on them. I also got some more finish sanding done on the helmet. I find it hard sometimes to know how done is done when preparing a piece for molding, but since I need to cast at least six of these, its worth the time now to get it just right. On another note, I am quickly approaching the time to start the next part of the build. I'm trying to figure out if it would be best to start the gauntlets or the jet-pack, or the night owl helmet for my wife...

    Day Six Pictures:

    day-six-1-3-jpg
    Helmet parts coming together.

    day-six-3-3-jpg
    You can see the size difference in the left ear piece. I figure I'll save the smaller parts set for the night owl helmet.


    day-six-2-3-jpg
    Only need to install the ears, cut in the "turn signals", and complete the finish sanding, then I'll be ready to mold.
  10. eqdizzle's Avatar
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    Jul 21, 2014, 11:36 AM - Re: Building Armor for Star Wars Celebration 2015 #10

    Nice work sir!
  11. RalfSkunk's Avatar
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    Jul 21, 2014, 7:45 PM - Re: Building Armor for Star Wars Celebration 2015 #11

    Thanks! I got to tell you its nice to get some feedback. I was thinking it might be worth trying to add a cricket chirping sound to the thread when people view it, but nobody would get it.

    I should also take a moment to thank wizardofflight for the templates... Thankyou wizardofflight! I modified these quite a bit, but I could not have had a better starting point for this project.

    Besides this, no pictures for today as I promised the wife I would hang out with her once in a while. Let's see if I can trick her into a romantic evening of downloading areana jet-pack templates or making a pattern for a deathwatch flightsuit... (I'm totally sleeping on the couch if she reads this!)
  12. RalfSkunk's Avatar
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    Jul 23, 2014, 12:13 AM - Re: Building Armor for Star Wars Celebration 2015 #12

    Another day of progress has come and gone. I started a pep build for the arena backpack today. The size seems pretty good, but I didn't find any build threads showing how well this comes together. I guess I didn't really look too hard, but who has time to do that when there is so much stuff to build. I really didn't get too far before jumping ship and heading out to the shop to work on the helmet some more. I'm pretty close to having the helmet done at this point, and should be ready to start molding it this next week.

    day-seven-1-7-jpgday-seven-7-7-jpg
    Here's the jet pack, this may be my weekend project.

    day-seven-2-7-jpg
    Here is the left ear piece attached to the helmet.

    day-seven-6-7-jpg
    And the right ear pieces.

    day-seven-5-7-jpg
    The helmet is nearing completion.

    day-seven-4-7-jpg
    And then I put the project away for the night. If I finish it in time, I might even make another costume...
    Last edited by RalfSkunk; Jul 23, 2014 at 12:39 AM.
  13. RalfSkunk's Avatar
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    Jul 25, 2014, 2:03 AM - Re: Building Armor for Star Wars Celebration 2015 #13

    And my helmet is done... almost. I still need to make up the range finder before I can say its really done, but I'm pretty happy with it. I got the "turn signals" cut into the front of the helmet today, finished up the sanding, and got everything put into primer. I figure this weekend I'll give it a coat of some obnoxious color, so long as it is glossy, and get ready to mold it.

    Here are day eight progress pictures:

    1-jpg
    Hurray for turn signals...

    2-jpg
    Picasso would have been proud.

    3-jpg4-jpg5-jpg
    And here it is all in primer. I had to add the shot from the back as I don't think I posted one of these yet.
  14. RalfSkunk's Avatar
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    Jul 27, 2014, 12:14 PM - Re: Building Armor for Star Wars Celebration 2015 #14

    Not too much to write about; I got the gloss coat on the helmet this morning. Silicone is on order. Hopefully I'll be casting some helmets pretty quick here.

    Progress photos for the day:

    photo-2-jpgphoto-4-jpg
  15. eqdizzle's Avatar
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    Jul 28, 2014, 4:21 PM - Re: Building Armor for Star Wars Celebration 2015 #15

    Will you be offering these for sale once complete?
  16. RalfSkunk's Avatar
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    Jul 28, 2014, 7:36 PM - Re: Building Armor for Star Wars Celebration 2015 #16

    I don't see why not. The bike helmet base makes them a bit more narrow and taller than the real movie used helmets, but I think that works well for the Death Watch thing. My goal with the project is to make a movie style version of the Clone Wars charaters, and if others like it, I'll be happy to hook them up. Of course, I'm also planning on making vac-formed armor, resin gauntlets, and a jetpack as well... and probably even guns, so stayed tuned in, because I only have 261 days, 14 hours, and 23 minutes left to get it all done!
  17. eqdizzle's Avatar
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    Jul 29, 2014, 9:42 AM - Re: Building Armor for Star Wars Celebration 2015 #17

    RalfSkunk said: View Post
    I don't see why not. The bike helmet base makes them a bit more narrow and taller than the real movie used helmets, but I think that works well for the Death Watch thing. My goal with the project is to make a movie style version of the Clone Wars charaters, and if others like it, I'll be happy to hook them up. Of course, I'm also planning on making vac-formed armor, resin gauntlets, and a jetpack as well... and probably even guns, so stayed tuned in, because I only have 261 days, 14 hours, and 23 minutes left to get it all done!
    Lol..! I have a DW helmet right now that catches on my cheekbones. I had to use vegetable oil and wiggling to get it removed...OW!! I haven't trimmed out the visor area yet, and I'm debating whether to do a "back-off" or to widen the helmet by 1/2"...what to do!!??
  18. thorssoli's Avatar
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    Jul 29, 2014, 12:44 PM - Re: Building Armor for Star Wars Celebration 2015 #18

    eqdizzle said: View Post
    Lol..! I have a DW helmet right now that catches on my cheekbones. I had to use vegetable oil and wiggling to get it removed...OW!! I haven't trimmed out the visor area yet, and I'm debating whether to do a "back-off" or to widen the helmet by 1/2"...what to do!!??
    My very first Fett helmet was an eBay find several years ago. I was so excited to try it on that I didn't give it a moment's though when it turned out to be hard to get over my head. Then I spent the next 20 minutes prying and pulling and twisting before I finally managed to wiggle out of it. I can attest that unless you have a gargantuan melon head that makes hat shopping impossible, this version will fit. In my mind there's no choice to be made. You need one of these.

    On a different topic, I printed out your rangefinder parts on the Objet30:
  19. Jul 29, 2014, 1:09 PM - Re: Building Armor for Star Wars Celebration 2015 #19

    I like how it's turning out. On my next build I might have to cop one of these lol. I have a WMB bucket right now and it's big on me. And p.s. That arena pack is a pain in the a** to build. I started it yesterday for my jango and it's hard to cut the cones out. I'm about to give up and buy one.
    Last edited by Justicethebeast; Jul 29, 2014 at 1:19 PM.
  20. eqdizzle's Avatar
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    Jul 29, 2014, 2:04 PM - Re: Building Armor for Star Wars Celebration 2015 #20

    thorssoli said: View Post
    My very first Fett helmet was an eBay find several years ago. I was so excited to try it on that I didn't give it a moment's though when it turned out to be hard to get over my head. Then I spent the next 20 minutes prying and pulling and twisting before I finally managed to wiggle out of it. I can attest that unless you have a gargantuan melon head that makes hat shopping impossible, this version will fit. In my mind there's no choice to be made. You need one of these.
    That's great feeback...color me interested to say the least!
  21. RalfSkunk's Avatar
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    Jul 29, 2014, 7:09 PM - Re: Building Armor for Star Wars Celebration 2015 #21

    If anybody hasn't figured it out, I work with Thorssoli (my friend Shawn) in his shop from time to time... While I've never really sold anything through the dented helmet or the RPF, I'm sure he's already figured out a price and shipping costs. It's worth mentioning that while the bike helmet base is narrower, it is also a bit longer from front to back. I have a pretty big head, so I'm hoping this will be a good answer to all of us who don't fit the other helmets. I'll keep everybody posted.
  22. RalfSkunk's Avatar
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    Jul 30, 2014, 1:32 AM - Re: Building Armor for Star Wars Celebration 2015 #22

    And yet another good day of progress on the helmet. I got the helmet wet sanded with 360 grit paper and waxed in preparation of molding it, and I even got the print coat of silicone mixed up and onto the helmet... I just might be able to get a casting or two out of the mold this weekend. Then again, I have to go see Guardians of the Galaxy this weekend. Either way, enjoy the progress photos:

    photo-jpg
    Wet Sanded with 360 grit.

    photo-5-jpg
    Waxed and prepped for molding.

    photo-1-jpg
    Stealing materials from my friend Shawn...

    photo-2-jpgphoto-3-jpg

    I'm the guy with the big head... in the front of the picture - as opposed to the guys with big heads in the back of the picture.

    photo-4-jpg
    Print coat of silicone is done.
  23. thorssoli's Avatar
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    Jul 30, 2014, 10:33 AM - Re: Building Armor for Star Wars Celebration 2015 #23

    You forgot the money shot:
  24. eqdizzle's Avatar
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    Jul 30, 2014, 11:24 AM - Re: Building Armor for Star Wars Celebration 2015 #24

    Ok...so one dumb question...from what I can tell none of the DW grunts have the "turn signals". These would have to be filled in and smoothed to get a 501st approval, right? Or is this for custom Mandos?
  25. RalfSkunk's Avatar
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    Jul 30, 2014, 7:50 PM - Re: Building Armor for Star Wars Celebration 2015 #25

    You bring up a valid point, and it was discussed at length before I started the build. The short of it resulted in that they would be easier to fill after the fact then to cut them in if we decided that we wanted them.

    As to what I am planning to do on my costume, I'm going to have them. The clone wars series uses a very stylized helmet for the Death Watch guys. The critical point for me was that they did show the Jango Fett helmet in one episode and it was the same stylized helmet that the Death Watch guys were using (although it did show the turn signals). As I'm looking to build a Death Watch uniform/armor that looks like it was from one of the movies and not the cartoon, I figure that every movie mandalorian helmet had these, so why wouldn't these ones.

    I looked into the 501st requirements a bit as well and it looks like they require animated style helmets. As I'm aiming for a movie style helmet of the animated character, these will not likely qualify for use with the 501st without some modification. While the turn signals will be easy to fill, I shaped the visor very much like the movie helmets and not the animated series. This will not likely be an easy modification. Of course if they include death watch guys in the upcoming Boba Fett movie, I just might be ahead of the game for once.
    Last edited by RalfSkunk; Jul 31, 2014 at 12:27 AM.

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