Boba Fett Helmet Blueprints/Templates

LOL two inches,... LOL

Does anyone have any idea on what to use to make the mold with? Id like to make mine out of some sort of plastic, but no idea what to use, Ive read here that someone was going to use spray on rubberized undercoating. But does anyone know anything else to use? Something more like hard plastic when cured.

I have finished off, elmers glueing everything, and systematically removing all the masking tape. I have used cardboard cut outs of the rear sections, and the visor cut out, and inserted them and glued them in place to make the negative of the raised areas on the helmet. Yet now closing in on the actuall casting portion itself, Im at a loss, of what to use that will end up as a hard plastic (like most toys). Id use glass but Id prefer something a little less messy. Id use plastic weld but it would take days, as I can only mix small amounts at a time.

What was the stuff they used in the special features when they showed them making the dome for vader? It was pigmented, and looked fairly easy to work with.
Any other ideas?
DM
 
No, its not a cardboard helmet. LOL

Its made of poster board from WOF's plans. On the indside of the helmet I have placed card board where the T is in the Visor, and on the back of the inside below where the ridgeline of the helmet is.

Being that the inside of the posterboard helmet is in fact a negative, I using the cardboard which was rolled with a sheetmetal roller to keep it from kinking. to get the contours and ridges I need.

Im going to smear a thin coat of silicone caulking on everything inside to act a release agent. But Im not sure of the best plastic material to use for the casting material, that is readily available from a local store.

Waiting 6-8 weeks via mail order for a replenishment of casting matl, or anything gets to be a pain. And I'd like to try something different than Epoxy if I can.

I found out about waiting for shipping,when I discovered a source for the star wars paints from the OT, and ran out in the middle of my vader project.


Im looking to make this bucket out of some sort of durable plastic. something alittle easier to tool. and less hazardous to my lungs.
 
I'm planning on finishing mine out of PCV sheets. Which is why i'm spending so much time messing around with the cardboard and paper versions of it now. I want to be sure that eveything is going to line up and still fitt my noggin when all is said and done. The nice thing about the PVC is that you can take your flat patters, heat them, and roll them into shape. and if they don't quite roll right, you can always re-heat them, and try again.
 
Well the first coats of resin are going on today.

heres you can see the cardboard inside to give the T visor depth when the glass is done being layed down.
dsc01325nr9.jpg


And here you can see the cardboard pieces installed inside to give the dome ridge depth
dsc01324zs9.jpg

dsc01323sz2.jpg


This will get several coats of resin alone, before adding glass for reinforcement later.

Once I get my batting helmet I'll section it as needed and glass that down as well to the already glassed lower portion, making them one piece.

After the resin is sufficiently thick Ill sand/peel away the paper and cardboard to leave only fiberglass. Im sure this will take several months to complete with my schedule. LOL

Just thought Id toss up an update.

DM
 
I wanted to thank WOF, I used his Templates, so I figured the best way would be to show my progress on my scratch built. I have been lurking here for a while and have never really tried anything like this. so her goes.


mandohelm2.jpg



I built the dome part by laying glass over my old Kevlar helmet, covered with a trash bag, It's thin but quite strong. I messed up a couple gluings so it's a bit on the messy side. It's rough but a start. I didn't make it deep enough, so I will make a new one after I get this one put together, so I can understand the structure a little better.

dome3.jpg


profile

dome2.jpg


It's not a bad shape and if I get a better depth on my next try, it might be acceptable for my second attempt. It's almost dead on dimensions given in the templates.

dome1.jpg


In any case I will continue to work on it as I am able.

-x
 
well, i'm on hold till i get some money together. thanks to school i haven't had a paycheck in a couple months, so as much as i'd like to go Mando, it'll have to wait a little while longer
 
Well I just printed the templated out to try and get a better grasp of how the angles of the helmet go together and it went so well that I think I'll run up a plastic version and get painting! Thanks for the awesome templates!!!
 
Hi yall, I am new here, already before I read in this forum a lot, and I am very happy to find you. In the internet I was looking for a good template to make a 3D Boba Helmet, and I found this CAD paper template here. And I must say your template here is a dream wizardofflight ! Great job ! And its even more fun than building it digitally!
In 2,5 hours I had a perfectly shaped Boba Fett helmet !

Look at the dome, it looks great for me. I had no trouble with any pices, it was almost easy to put this together.
A riddle for me is still the band around the helmet from the visor to the back of the helmet. When I will build the band, the cheek bones will be too deep inside the helmet wouldn't they, what you think. Do you have the exact dimensions of this band, specially how thick it is?

See ye later ! Bye, Chris
PaperBoba00.JPG

PaperBoba01.JPG

PaperBoba04.JPG

PaperBoba06.JPG
 
Beautiful work!! Very glad that they work out so well for you!

As for the thickness of the band it is about 1/16" to 3/32", it is a difficult number to pin down as the thickness is not consistent. Being that it is only about 1/16" it really shouldn't have too much effect on the depth of the cheeks. I would suggest that when you do apply the outer layer that you leave about 1/2" overlap in the cheekbone area so that it can be trimmed to match the cheek's angle. Hope that makes sense.

Can't wait to see more pics. If you have any questions just let me know.

Alan

Hi yall, I am new here, already before I read in this forum a lot, and I am very happy to find you. In the internet I was looking for a good template to make a 3D Boba Helmet, and I found this CAD paper template here. And I must say your template here is a dream wizardofflight ! Great job ! And its even more fun than building it digitally!
In 2,5 hours I had a perfectly shaped Boba Fett helmet !

Look at the dome, it looks great for me. I had no trouble with any pices, it was almost easy to put this together.
A riddle for me is still the band around the helmet from the visor to the back of the helmet. When I will build the band, the cheek bones will be too deep inside the helmet wouldn't they, what you think. Do you have the exact dimensions of this band, specially how thick it is?

See ye later ! Bye, Chris
PaperBoba00.JPG

PaperBoba01.JPG

PaperBoba04.JPG

PaperBoba06.JPG
 
Thank you wizardofflight for your help ! Where is the thickest part of the band, for me it looks like in the back, is that correct?
I hope I can work more on the helmet soon, its fun ! But I am pretty busy in the last time. For sure I will inform you as soon something major has changed.
How far are you with your bucket? How do you build the ears? I plan to sintering them by laser. I have inexpensive "connections" :)
From where did you take the measurements of your CAD helmet?

I would suggest that when you do apply the outer layer that you leave about 1/2" overlap in the cheekbone area so that it can be trimmed to match the cheek's angle.
It makes absolutely sense to me, good idea !

Till later, Chris
 
I have a question. I am guessing that I see references to WoF's template no less than 5 times a week, probably more. Why aren't they stickied? They are a free resource given to the community and should be a little more prevalent. Just a question, maybe this issue has been addressed before.

-x
 
Hi.
First I must say: WOF, you are the man!!!(y)
What would we do without you???

For the dome I also use a skater helmet which I bought on eBay for 2.5€.

First I thought that the top is too flat but it´s ok, isn´t it?

These photos are made after one coat of resin. There will be 3 or 4 more coats berfore I use fibreglass.

What do you think?

P6120113.jpg


P6120115.jpg


P6120117.jpg
 
How in Julia's name did I over look this? :eek: Very nice templates Wizard! :cheers
 
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That looks great! Beautiful job! That helmet is a great match, plus you don't have to worry about padding. Can't ask for better than that.

Please keep me posted, can't wait to see the final product.

Alan

Hi.
First I must say: WOF, you are the man!!!(y)
What would we do without you???

For the dome I also use a skater helmet which I bought on eBay for 2.5€.

First I thought that the top is too flat but it´s ok, isn´t it?

These photos are made after one coat of resin. There will be 3 or 4 more coats berfore I use fibreglass.

What do you think?
 
Here's one for you PDF gurus....I need to enlarge Alan's templates by 107%, but I don't see an option for changing the scale incrimentally on my Adobe print option....how can I do this?
I also have AutoCad 2004 & 2007, and an HP 430-D plotter....can I somehow print them using one of these programs?
Rob
 
Since you are running AutoCAD just send me an e-mail and I will set you up with the CAD files for whatever you need.

Alan
wizardfoflight@comcast.net

Here's one for you PDF gurus....I need to enlarge Alan's templates by 107%, but I don't see an option for changing the scale incrimentally on my Adobe print option....how can I do this?
I also have AutoCad 2004 & 2007, and an HP 430-D plotter....can I somehow print them using one of these programs?
Rob
 
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