Silverstalker
Active Hunter
You can also weld it with a regular propane torch.
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Counterweight's Second ROTJ Cardboard Scratch Build
- Thread starter Counterweight
- Start date
bobawannabe
New Hunter
Do you have a link to the templets??
Counterweight
Hunter
That took foreeeever to cut out
While i was waiting for the glue to dry on the key slots, I figured it do a minor detail I've been neglecting
Now to install the key slots
And the final result
bobawannabe
New Hunter
Thanks for that, will be starting my own helmet build soon, fingers crossed!
Counterweight
Hunter
Yeah... Not sure what to expect with Raf's dome templates. They look like they will work out a little better. I'm hoping
Counterweight
Hunter
Okay so I got the dome done. Overall it didn't turn out too bad, despite a couple small snags here and there
First I cut out the dome base. I left about a 10mm rim
Then it was time for the dome support rings. This is one aspect of Rafal's build that I much prefer over the WOF build. The extra transversal supports provide a lot more structural integrity to the build
Ugh... Now for my least favorite part of the entire build. Those damn dome slices!
So after spending a couple hours cutting them out, I misted the slices and preformed them. I let them dry overnight
Now the difficult task of using the hot glue gun to get those bad boys on the bucket. It did go relatively painlessly because of the terrible experience I had with this on my last build. That experience was invaluable as to what NOT to do
Rafal's build thread says to put the dent in before glueing in the last section, but I was having issues with this, so I decided to glue it in first, then do the dent
After using a sharp blade to trim down the high points, I put in the front arrows and the dent
I didn't notice this before, but the line between the front two dome slices is just a mm or two off center. So when I put the arrows in, they look a little off center, but they are centered compared to the t-visor center line.
When I put the dent in the bottom slice fell off a little and looks kind of funky, but that's what bondo is for
And this is the final result
So I'm going to attempt to do the ears according to rafalfett's technique, but I don't have any 1 mm cardboard so we will see how it goes. Maybe I can split some of my 2 mm cardboard or something. I don't know, but I'll figure something out
First I cut out the dome base. I left about a 10mm rim
Then it was time for the dome support rings. This is one aspect of Rafal's build that I much prefer over the WOF build. The extra transversal supports provide a lot more structural integrity to the build
Ugh... Now for my least favorite part of the entire build. Those damn dome slices!
So after spending a couple hours cutting them out, I misted the slices and preformed them. I let them dry overnight
Now the difficult task of using the hot glue gun to get those bad boys on the bucket. It did go relatively painlessly because of the terrible experience I had with this on my last build. That experience was invaluable as to what NOT to do
Rafal's build thread says to put the dent in before glueing in the last section, but I was having issues with this, so I decided to glue it in first, then do the dent
After using a sharp blade to trim down the high points, I put in the front arrows and the dent
I didn't notice this before, but the line between the front two dome slices is just a mm or two off center. So when I put the arrows in, they look a little off center, but they are centered compared to the t-visor center line.
When I put the dent in the bottom slice fell off a little and looks kind of funky, but that's what bondo is for
And this is the final result
So I'm going to attempt to do the ears according to rafalfett's technique, but I don't have any 1 mm cardboard so we will see how it goes. Maybe I can split some of my 2 mm cardboard or something. I don't know, but I'll figure something out
Silverstalker
Active Hunter
Looking good, taking your time is paying off 
Counterweight
Hunter
Looking good, taking your time is paying off
Thank you sir!
Counterweight
Hunter
The ears have been intense! I decided for the 1 mm parts I would just split the cardboard with a knife. I went with the right ear first
Problem: I forgot to cut out the slot for the Honeywell micro switch before gluing all the pieces together. So I had to cut the section out afterwards which wasn't easy
Now for the ear cap
This highlights a major difference between rafal's templates and the WOF templates. Doing the ears this way is significantly more labor-intensive (having to cut out all of the little supports) but it seems to be more sturdy, lightweight, and in my opinion looks cleaner.
Lower portion of right ear
I layed them on top of the helmet in order to make sure they fit. They do!
Well that's it for that side! I'm about halfway through cutting out the 30+ supports for the left ear so I'll do a short update on that tomorrow. Then it's on to the RF!
It's getting there slowly but surely
Problem: I forgot to cut out the slot for the Honeywell micro switch before gluing all the pieces together. So I had to cut the section out afterwards which wasn't easy
Now for the ear cap
This highlights a major difference between rafal's templates and the WOF templates. Doing the ears this way is significantly more labor-intensive (having to cut out all of the little supports) but it seems to be more sturdy, lightweight, and in my opinion looks cleaner.
Lower portion of right ear
I layed them on top of the helmet in order to make sure they fit. They do!
Well that's it for that side! I'm about halfway through cutting out the 30+ supports for the left ear so I'll do a short update on that tomorrow. Then it's on to the RF!
It's getting there slowly but surely
Counterweight
Hunter
Thanks!
Counterweight
Hunter
And the left ear
So... Many.... Supports....
It took forever
But I think the end result wasn't too bad. Like with the other ear, a little TLC with the dremel around the edges and it should look just fine
Up next the RF stalk and the RF
So... Many.... Supports....
It took forever
But I think the end result wasn't too bad. Like with the other ear, a little TLC with the dremel around the edges and it should look just fine
Up next the RF stalk and the RF
Stormcrow85
Hunter
I have started this helmet as well man. Looks like you are a couple days/ a week ahead of me, so:
1. Don't let me catch you!
and
2. Keep the pictures coming so I can plagiarize!
1. Don't let me catch you!
and
2. Keep the pictures coming so I can plagiarize!
Counterweight
Hunter
Stormcrow85
Hunter
Bro you better hurry! I am catching you! You get anything done on it this weekend?
Counterweight
Hunter
Bro you better hurry! I am catching you! You get anything done on it this weekend?
Why yes in fact I have!
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Counterweight
Hunter
Quick update: all of the cardboard part of the build is pretty much done!
I can't for the life of me figure out how to cut out decent circles from this chipboard, so it looks a little rough. But all of the pieces are going to be smoothed out with the Dremel soon so it will look a lot more polished once I do that
And then for the rangefinder itself
I want to do a clear Perspex block, but I don't know whether I'll be able to make it or just buy one. If anyone knows anything about it feel free to let me know!
This is everything I have so far
After a quick touch up on the ear parts with the dremel it will be time to start on the dome bondo... :/ not looking forward to the process, but I am looking forward to the end result
I can't for the life of me figure out how to cut out decent circles from this chipboard, so it looks a little rough. But all of the pieces are going to be smoothed out with the Dremel soon so it will look a lot more polished once I do that
And then for the rangefinder itself
I want to do a clear Perspex block, but I don't know whether I'll be able to make it or just buy one. If anyone knows anything about it feel free to let me know!
This is everything I have so far
After a quick touch up on the ear parts with the dremel it will be time to start on the dome bondo... :/ not looking forward to the process, but I am looking forward to the end result
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Stormcrow85
Hunter
Woot! Keep up the good work.
