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Boushh Helmet WIP

  1. #76
    Skupilkinson's Avatar
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    Jan 2007
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    Re: Boushh Helmet WIP

    Do you have a mouse sander? If you've used too much filler for the outer layer don't panic!

    I did that on my first attempt at this sort of thing. Just sand it right back, you'll start to see the card underneath and that's when you stop. Try to follow the card underneath to sand it to the shape it should be. Fortunately Boushh is a pretty simple lid to sand back and you should be fine.

    If you do decide to start over though, you just need to skim the surface with the filler. When you're sanding, card will start to show through and again stop there. Then build up a second layer to smooth it further, filling any dips or recesses from the first layer. That's how I did my custom Mando lid and it worked great! Too little is easier to work with than too much.

    As for the air bubbles. That's an easy fix. Do you have a Dremmel or similar mini tool? Use the sanding bit, it looks like a drum/cylinder. Use that to sand through the fibreglass and to break through the bubble. Sand it smooth so that there's a patch of card that is no longer covered with fibreglass. Than once you've got rid of all the bubbles, re-fibreglass those areas, taking more time and care to avoid new bubbles. I also use generous ammounts of resin in these tight awkward corners so that the excess resin kinda forms into pools and fills up those recess areas. It prevents bubbles should the fibreglass itself not stay in position(which can happen if you've not trimmed the fibreglass into reqired shape. Remember, the inside of you lid doesn't HAVE to be pretty. So long as it's doing it's job. Unless you plan to decorate the inside too. In that case you need to take care fibreglassing to get the best finish. Cutting fibreglass to shape to fit properly into tight areas. I also use wodden cocktail sticks ur wodden BBQ skewers to press the FG into position in those pesky tight areas.

    Small air bubbles aren't the end of the world but the big ones can cause problems.

    Looking forward to the pics mate!!

  2. #77

    Member Since
    Mar 2008
    From
    Limerick, Ireland
    Posts
    261

    Re: Boushh Helmet WIP

    Hey Skip!

    Thanks for the ideas! I do indeed have a mouse(ish) sander and looking over your post - things might not be as bad as I think... Ive attached pics below to explain my problems... hope this is ok with everyone?

    Also PLEASE NOTE - these issues are with the fact this is my very very first full build and nothing to knock about the excellent templates!

    OK so on with the state of the union: I gave this a quick coat of grey primer to make things a bit more uniform...

    Firstly a general look - I think my issues arise from the fact that I put the complete template together, forgetting about the closed off areas that need fiberglassig BEFORE being attached to the helmet:



    ---

    Secondly - the circled areas are parts where the air bubbles/unset fiberglass is causing warping. The arrow is to the area I'll have to remove as the top visor and 'snout' have no glassing support inside at all:



    You might notice the colour change at the back of the neck... I started with Fiberglass cloth (darker) and changed to Fiberglass cotton - its easier to work with but I feel it caused some of the problems Im having with trapped air...
    ---

    Third - The ear will have to come off as above, there is no support! Doh! The back of the head, has air bubbles so moves to the touch:



    ---

    Fourth - Just a top view. Im not sure if it came out in the pic but as Skip said Some areas are down to almost the bare card - I think this top part is ok?



    ---

    Next is just a back view. One side of the upper part is bondoed the one without the arrow has none. You might be able to see the arrow area is lower (and correct) while the opposite side is higher as it warped without fiberglass support:



    ---

    On to - Other side. The unbondoed area needs Fiberglass reinforcing and the ear has to come off:



    ---

    And finally, all the issues together. Working from the top - The top 'visor' part has no glass underneath so I might just remove that and re-do it. The actual area you look out is fine, just needs bondo. The unbondo'd side should be fine with more FG. Might just cut off the entire front as its just paper and the bottom rim parts should be ok to straighten with careful FG work...



    ---

    Ugly SlideShow



    So what do you guys think? Looking again, Im not as sure as I was that it is a writeoff...

    Anyhoo - Thank you all for the comments... again I cant express how much of a fantastic learning experience this is. As long as I can learn form my mistakes Im a happy bunny

    Thanks folks!

    Dave

  3. #78
    FettSniper's Avatar
    Member Since
    Jul 2007
    From
    Sarlacc pit a.k.a Diss Norfolk UK
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    347

    Re: Boushh Helmet WIP

    How much are the plans for this helmet being sold for? Very interested in making one myself

  4. #79
    Skupilkinson's Avatar
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    Jan 2007
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    Wales, UK
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    Re: Boushh Helmet WIP

    Thanks for the interest buddy.

    It's all detailed at my blog, the link is in my sig here.

  5. #80
    Skupilkinson's Avatar
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    Jan 2007
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    Wales, UK
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    Re: Boushh Helmet WIP

    I thought I'd add a note for the construction of the Boushh lid. Just the way I envisioned it when I designed the model and templates.

    Build the main helmet all as one piece, then you'll be left with things like the ears, snout pieces and sensor that sits above the visor.

    Build these parts and glue them into position on the main lid.

    Now you'll have hollow areas inside these parts that you won't be able to access when fibreglassing. Not to worry, I encountered this problem when building my custom gauntlets. You need to carefully mark out where these pieces are on the inside of the lid. So you'll have a pencil outline showing you where to cut. The card should be thin enough to allow light to pass through and give you a general idea of where to mark these areas out.

    Using a sharp, fresh blade on your knife, gently cut out the un-needed card from the main helmet where you marked out earlier.

    If you've taken your time and got it right, you'll now have access to the pieces(ears, sensor above visor, and snout) when you come to fibreglass. Any excess card remaining can carefully be trimmed away first.

    Anyone who's tried to build be Pepakura Fett gauntlets will have encountered this when building them and may have come up with this solution themselves or an alternative.

    As I said, this is what I did for me Custom Gauntlets and it worked a treat. Providing you use plenty of glue to secure the parts and wait long enough for the to dry fully and set.

    I know this may come a little late for some - Sorry McKenic - but I hope that it will prove useful for fixes or new builders.

    McKenic, I think your lid can be fixed buddy. Too much filler is a pain but not the end of the world mate. You know how to reach me if I can help more.

  6. #81
    t_bone9600's Avatar
    Member Since
    Dec 2005
    From
    Jackson, Ohio
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    855

    Re: Boushh Helmet WIP

    I agree with Skip. It can be saved. Just take your time and give it a little TLC and it willl be alright.

  7. #82
    Skupilkinson's Avatar
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    Jan 2007
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    Wales, UK
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    Re: Boushh Helmet WIP

    Yeah, and T-bone knows all about it. The time he put into saving his RG lid rather than scraping it and starting over was really well spent!

  8. #83
    Stormrider's Avatar
    Member Since
    Aug 2007
    From
    Kalamazoo, MI
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    2,235

    Re: Boushh Helmet WIP

    This is probably something all of you know, but i thought id mention it.

    Ive seen artists when I was in school build things out of cardboard (non corrigated) stock.

    They then spray a watered down (or paint on) wood glue on it. It hardens it. A couple of coats and its REALLY HARD. It would work very well for a base for resin/bondo.

    I love watching these. But you better wear a mask when you sand that bad boy

  9. #84

    Member Since
    Mar 2008
    From
    Limerick, Ireland
    Posts
    261

    Re: Boushh Helmet WIP

    Thanks folks!

    Im beginning to see this as a challenge rather than a disaster... I'll be slow with the updates but promise to document and post them. Might be some help to someone!

    Thank you all again!

    Dave

  10. #85
    Skupilkinson's Avatar
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    Wales, UK
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    Re: Boushh Helmet WIP

    Good point, thanks Storm'.

    I used the same glue for the card construction of my Mando lid. It works a treat especially if you laminate card together as I did to thicken the card.

    I'd still recommend fibreglass though to toughen it further.

    Looking forward to those updates Dave.

  11. #86

    Member Since
    Oct 2009
    From
    Manchester, England
    Posts
    16

    Re: Boushh Helmet WIP

    This is the thread that made me join this forum and begin researching and preparing for my new found hobby! Thanks Skip (and darn you Skip at the same time lol) Can't wait to get stuck in, this community seems great and very helpful looking forward to starting my first project with this helmet. Already PM'd you Skip about buying some of your pepakura files! Can't wait to see a finished version of this too.

    Oro

  12. #87
    Skupilkinson's Avatar
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    Re: Boushh Helmet WIP

    Just about to reply.

  13. #88

    Re: Boushh Helmet WIP

    can somebody post a helmate template. im in need of one and i cant find it

  14. #89

    Re: Boushh Helmet WIP

    What ever happened to this guy? I'm in need of the boushh pep and he doesn't seem to be active anymore. I haven't been able to find the pep anywhere else. Can anyone help me out here?

  15. #90
    Skupilkinson's Avatar
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    Jan 2007
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    Re: Boushh Helmet WIP

    I'll be replying to your email soon.

  16. #91

    Re: Boushh Helmet WIP

    Skupilkinson said: View Post
    I'll be replying to your email soon.
    You're still here! It showed your last activity as a year ago so I was worried.

    I look forward to it.

    Thanks

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