Not your average ROTJ scratch build

[Counterweight]

So after spending a ton of time perusing TDH, I was inspired to do my own scratch build. Problem is... I suck at scratch building. So I decided to utilize the amazing amount of talent and know-how on this site in a somewhat unique way.
I've decided I will post my WIP boba bucket on here, even though it is somewhat intimidating to do so, compared to other people's. My hope is that this build will receive plenty of constructive criticism as I go along, and will teach me a hell of a lot for my next helmet (which I'm hoping will actually be halfway decent). The other purpose of this thread will be to show other scratch build newbies the MANY mistakes I've made along the way, in hopes that maybe they can avoid some of those themselves.

As I post, I'm going to explain things I have done wrong along the way, and hopefully will get some tips for how to improve. We'll see how it goes.

That being said, let's get started!


I used the WOF templates and loosely tried to follow the Antman build, among others.

I immediately ran into the issue of finding greyboard. So I had to go with 2mm chipboard, and I had such a tough time cutting through it. I was also using the wrong type of knife, which didn't help

Very jagged lines were due to the tough time I had cutting the chipboard.

Next mistake I made was fully cutting out the t-visor area, which compromised the structural integrity of the bucket.

Well, that's it for the first update. Clearly the lack of ability to cut straight, smooth lines had a negative impact, but I'm not gonna let it stop me
Quick question: what is the most effective way to transfer the templates to the cardboard? I tried gluing them and then cutting them out, but that didn't work well. I settled on cutting the templates out, then taping them down and tracing them. Any other techniques?

I'll try to do the next update soon, and any criticism or advice is more than welcome. Trust me, I NEED IT.

Next up: the dreaded dome!

 

[Armydad]

Not a bad start at all, just glue another visor in place to help strengthen it until you're further along. Keep with it, you're doing fine.

 

[Counterweight]

Not a bad start at all, just glue another visor in place to help strengthen it until you're further along. Keep with it, you're doing fine.

Probably something I should've thought of myself lol
Thank you!

 

[Artakha]

Nice start! I have been doing one recently which has progressed quite a ways but currently on hold. Maybe it will help you a little.

Le1120's Second Cardboard Helmet Scratch Build -- WIP

 

[Counterweight]

Nice start! I have been doing one recently which has progressed quite a ways but currently on hold. Maybe it will help you a little.

Le1120's Second Cardboard Helmet Scratch Build -- WIP

Yeah I've seen another build you did and it was really helpful. I hadn't actually seen this one yet though. Looks amazing. Will definitely be referring to it frequently. Unfortunately I'm farther along in my current build than the initial post shows, but for Fett Bucket V.2 I will certainly be viewing yours repeatedly.
I really appreciate the help!

 

[Artakha]

Good to hear it's helpful.

 

[Counterweight]

And now on to the dome!

I started with the two dome support rings, which were plagued again by my inability to smoothly cut the chipboard

I then sprayed and preformed the dome slices before glueing them

I went a bit crazy with the hot glue when glueing the dome slices together, and it unfortunately shows

All done!
When glueing the dome support rings I didn't initially put them on perfectly straight so I had to do some slicing and dicing in order to make the dome slices fit, but with the exception of a ridiculous amount of hot glue I made it work (kinda).

That's all for now. It's rough looking but at least it's starting to take shape a bit. Next update will be the rear key slots and possibly the ears (ugh) and also my struggles with bondo.

 

[Silverstalker]

That is normal to see it looking a bit rough round the edges with cardboard builds, a razor blade to slice down any high spots of glue will work, the filler part will smooth all that out, don't forget to fiberglass the inside it will make it solid

 

[Counterweight]

That is normal to see it looking a bit rough round the edges with cardboard builds, a razor blade to slice down any high spots of glue will work, the filler part will smooth all that out, don't forget to fiberglass the inside it will make it solid

Oh sweet I didn't know I was supposed to fiberglass the inside. Thanks!

 

[Counterweight]

Next I decided to try to do the rear key slots. It actually turned out better than I anticipated, yet still far from perfect.

When I cut out the back of the bucket to put the key slots, I guess I measured wrong so there was a slight gap on top and bottom. Not to worry, those will be covered with small pieces of cardboard

So I decided to start the bondo process next. Only problem is I have never used bondo before

I didn't read the directions and didnt add the hardener cream. This is actually really embarrassing to post, but maybe it'll help someone else who's new to all this

With all that scraped off I put bondo on correctly (although I think I put too much)

While letting that dry, I started working on the ears and the RF. This was the most intimidating part for me to do. I'll get into that in the next update later today. There are plenty of mistakes and room for criticism on the ear update, which I look forward to.

 

[Gregory]

I didn't read the directions and didnt add the hardener cream. This is actually really embarrassing to post, but maybe it'll help someone else who's new to all this

Oops! Reading the instructions helps sometimes I guess! Bondo is funny stuff, it will feel very plastic for a while until it fully cures. Be sure to let it cure before trying to do any sanding. Also fresh air is important.

 

[Counterweight]

Oops! Reading the instructions helps sometimes I guess! Bondo is funny stuff, it will feel very plastic for a while until it fully cures. Be sure to let it cure before trying to do any sanding. Also fresh air is important.

Yeah no kidding! Not my finest moment.
Yeah I actually over corrected at first and added too much hardener. Left myself only about a minute to apply it before it was too hard to spread. I'm learning slowly but surely thanks

 

[Counterweight]

Alright I think it's about time I show everyone these ears I attempted to make!

I'll start with the right ear. I had a really hard time finding threads that went in detail as to how to do the ears, so I decided to try to do the MTE from antmans build. It worked out okay, but I had a tough time get crisp sharp edges when sanding.

Also I sanded a little too aggressively in one spot

Same issue with the left ear and getting sharp, defined edges.

I wanted to use magnets to keep the earcap on the left ear, but the magnets i had were slightly too big, so I just used one instead of two or three

It fits tight enough so that the RF stalk doesn't fall on its own

Then finally the RF

Now that the ears are all done just have to spot check the bondo on the dome a couple times and then sanding, sanding, and more sanding!

After a couple more rounds of bondo, this is what I have

I want to get that dome a little smoother, and then in the next update its on to the arrows and the dent

Let me know anything I could improve on if you see it. I'll take all the help I can get!

 

[Utri4861]

You might have a better time using MDF for the ears. You won't get those lines throughout.

Sent from my SM-G900P

 

[Counterweight]

You might have a better time using MDF for the ears. You won't get those lines throughout.

Sent from my SM-G900P

What's MDF?

 

[Gregory]

MDF is Medium Density Fiberboard. It's used to make trim for houses. among other things. Cheap and easy to cut/sand/machine.

You have to be careful about getting it wet though, it will swell/spot.

 

[Counterweight]

Okay cool I just looked it up. The extent of my tools is pretty much a sanding block or a dremel. Would that be adequate to work with the MDF?

 

[Utri4861]

Okay cool I just looked it up. The extent of my tools is pretty much a sanding block or a dremel. Would that be adequate to work with the MDF?

Absolutely. It's very easy to sand, but still is strong.

Sent from my SM-G900P

 

[Counterweight]

Perfect. Thanks for the help guys

 

[Artakha]

Nice going! You're really plowing through this one. It's really important to document the mistakes as much as the actual progress for others to see and learn from. You're doing a good job! :cheers