Junior Jango Helmet scratch build WIP

I'm currently working on a Jango Fett Scratch build for my son. After finishing Boba at a 92% scale for my older son, the younger was perturbed (rightly so) about not also having his own awesome mando helmet, so I decided to make him Jango (because I'm crazy and hate my free time).

I started with Rafalfett's v1 templates, foamcore, sintra, cheap bondo fiberglass resin, and an el cheapo silicone caulk mold I made for the dome portion.


By the way this guy has a pretty good tut on making the mold. ...and says "actually"... a LOT. https://youtu.be/tBClhbrGR7w
It's a cheap way around dropping a bunch of money for making a 1 off mold...I can't say I'd do it again though. I managed to make it work, but I got no where near the results this guy did in his videos.


I have 2 layers of fiberglass in the dome...it will take a basball bat I'm pretty sure.



...and where I am currently.



I had to modify the key-slot configuration to match the Jango with a little more spacing....and the back-bottom portion of the outer-cheeks had to be widened a little. The dark stuff inside the helmet is Bondo Glass, which is thick resin premixed with fibers. I use it to give extra support to the stress points before I lay the inner fiberglass. I also JB-welded my T-nuts in beforehand so I could use the bondo glass to help reinforce them.

Coming along nicely!

Here are my CNC'd ears. I use hard maple because it happens to be what I have available. The programs are from RafalFett's (rafalworks) 3d warehouse models. I sized them down and moved the top and bottom right ear into one piece, since the Jango helmet is nearly connected anyway.





Rustoleum primer has been giving me a bad skin reaction from the overspray and fumes, so I tried to use some Valspar spray paint as primer...let me just say DO NOT USE THIS CRAP. It would not cure and I had to use Naptha to get it all off...plus a ton of sanding. It says on the can for wood/metal/plastic, but no. It just wouldn't cure.

Hear are some pictures I took before tearfully removing the paint.




Meanwhile I donned my hoodie, respirator and re-primed with good ole Rustoleum.




Finally after much wet-sanding I have some Rub-n-Buff on the back panels. I've never used this stuff...it was really fun to see it shine up!

Valspar is garbage from everything I've experienced. Unless you rub it down with wire wool prior to your next paint app. Otherwise it leaves a film that will only peel.

Sent from my LG-D851

Looking very nice. Keep it up!

I sprayed Rustoleum Royal Blue and Krylon Ocean Blue for the dark and light blues plus some rub-n-buff. This is right after removing the masking so I haven't done any touch-up to the paint or rub-n-buff yet.

Rangefinder...





Here is the finished Junior Jango Fett along side his brother PP1 Boba Fett! I have my WIP over here--> http://www.thedentedhelmet.com/f23/toeleven-junior-fett-scratch-build-wip-52997/




I have to say that I've learned so much during the process of building these...which would have never happened without the members of this forum! The problem I have now is I want to build another because I know I can improve on the last one!

SO COOL!!!!

Thanks! I appreciate it!

I agree what they said awesome work