First Time Build - Boba Fett Helmet - Cardboard - FINISHED

Magnavis · Sep 2, 2016

More of the same. First sanded the dome again, looking to target high areas. I then used my finger, running it over areas of the helmet, and looking for bumps. If I found one, I used the file to file it down until it was smooth. I did this all over where possible, which seems to have worked well. I then did the same again, but this time, looking for dips, and filling where I found them. I then had to do the same thing all over again once the filler had dried. Sand, file etc...I know have what I think is a pretty smooth surface. I am struggling with the dent though. I'm not that bothered about it being 100% accurate. aslong as it has some shape to it, I'm not fussed. I have a lot of needle files, so will have to use those and see what happens. Also been working on the coin slot, which is quite difficult to sand, as its small and awkwardly shaped. I'm also debating whether or not to leave the turn signals off or not. As I forgot to do them and it's now this far along, I don't want to mess it all up. But if I can find a way of cutting them out without causing lots of destruction to the dome, I will.

Artakha · Sep 3, 2016

I did my turn signals on my helmets using a small drill bit and a knife and metal files. They turned out well without damaging anything, but you do need to be careful. Looking good so far!!

Magnavis · Sep 3, 2016

Another coat of primer. For the most part the dome is now 'smooth'. There are a few imperfections. Main thing now is that there are lots of little flat point peaks if that makes sense. Where I've used the file to get the bigger bumps down, it has created flatter spots, and then lots of little bumps next to it all over. So more sanding to get those down and smoother. Also done some work on the dent, which is now looking much better. As I said in previous post, not too worried about it being accurate. Just slightly interesting in its shape. Gonna give it another sand, then then move on from the dome for a while, and focus on the cheeks. I'm still not sure at what point I should cut out the visor. It's seems most people leave it right until they are ready to paint, taking off just the outer layer of the visor?

tk675 · Sep 3, 2016

Looking great!

Artakha · Sep 3, 2016

If you take it off at this point your helmet will likely begin warping in that area without anything holding it together, so yes I'd wait till the last moment to take it off.

Magnavis · Sep 6, 2016

As promised, taken a little break from the dome for the time being. It's at a stage now where I'm more or less happy with it, and it's seems like it will only need minor modifications, and of course, more sanding! Started on the cheek areas. Left one wasn't constructed as well as the right one, so got some shaping to do. But first couple of base coast on and sanded. Seems like it's gonna be more straight forward than the dome. The little square on the right cheek, hard to get any files into that. Any suggestions?

Artakha · Sep 6, 2016

Put some bondo on it and sand. Don't forget that you will also want to seal the cardboard at some point before you paint or anything.

Magnavis · Sep 6, 2016

The whole helmet was coated with fiberglass resin before hand. I assumed that would be good enough? Exposed bit on pic was until recently covered up, and will be cut out anyway.

Artakha · Sep 6, 2016

Yeah that should do the trick. I couldn't tell from the pictures, and it had been something I had neglected to do till a late stage on my first build.

Magnavis · Sep 8, 2016

Cheeks coming along nicely

Magnavis · Sep 9, 2016

I'm getting there. All but run out of filler now though, so will probs wack a coat of primer on whole thing tomorrow and then wait until more filler comes..

But I think I'm almost there now..nearing closer to the finish anyway!

Magnavis · Feb 11, 2017

I'm back! Yay?

been away from it long enough. No pics atm, but basically, as I'm sure you can guess, more sanding and filling. Another sand today, followed by some primer, and HOPEFULLY! it will be close to a stage where I can start painting it, which I'm really looking forward to.

But I have a question. Is there something I can coat the inside of the helmet with? It has the fibre glass, but it's ugly. I could Paint it black I guess, but I was wondering if there was anything I could put on the inside that will hide the fiber glass, but also add that little but more rigidity?Some kind of plastic/glue paste? Was gonna stuff inside with foam anyway once done. Will post some pics later

Artakha · Feb 11, 2017

You'll want to add some padding at some point for actual wearing, so that's something to consider, and which would hide the fiberglass to some capacity. I suppose you try something like XTC-3D (meant for 3D prints) for strength and smoothness.

Magnavis · Feb 12, 2017

Left the paint for 24 hours as recommended. I think I'm pretty close now. Got everything pretty smooth, no large imperfections. Main problem now is just scratches from the 60 grit paper. So If I give it all another light sand and go through the grades, it should smooth it out nicely. Tiny bit of filling in the dent, which I'm pretty happy with. Cheeks and back panels are surprisingly smooth, with a tiny but of filling on right cheek needed. Ear pieces are also looking ok. Only problem I've had is in some places I've sanded back down to the cardboard. So will probably seal those area with PVA before continuing. Once it's all sanded, and at a state where I want to start painting, what do I do then? Do I need to seal it with something? Clear coat? Resin? Also, would now be a good time to remove the visor?

Artakha · Feb 12, 2017

I think you can just begin painting on top of the primer. I've used polyurethane for a sealant before, for that's only needed for exposed cardboard.

Magnavis · Feb 12, 2017

Alrighty, saves extra messing about then I guess. In regards to the humbrol paint, do you use the acrylic or enamel paints?

Artakha · Feb 12, 2017

Magnavis said:
Alrighty, saves extra messing about then I guess. In regards to the humbrol paint, do you use the acrylic or enamel paints?

Enamel.

Magnavis · Feb 13, 2017

So I've done a sand of one of the back panels to see how well it comes out, and to my amazement, it has come out incredibly smooth, and has a slight sheen to it, which is what I was hoping for, but didn't expect. Pics don't really show much though, as the colors hide it. I also realised that the dome wasn't in as good a shame as I thought it was, and so have decided to work on that some more. I made quite a thin mix of my filler, and applied quite s bit over the dome. Needs sanding, but going to give it 24 hours to dry, as there was more PVA in there than I usually use. I also (finally) started working on the ear pieces. I have also decided that I am going to make a cast of them (because why not) to use on the helmet. Can get a moulding and casting kit for just over £20 each, so thought I'd give it a go. Something new to learn I guess...Will post some more pics of dome tomorrow once it's all sanded. hoping to get rid of some of those lumps, bumps and flat spots. Can then start sanding the rest of the helmet in preparation for painting.

Those little ear piece supports were a pain in the butt to cut out!

Magnavis · Feb 15, 2017

Guess what I've been doing?
'Sanding and filling?'

Yes...

So....After priming it the last time (see above), I realised that the dome wasn't in as great a shape as I thought. Was quite lumpy, and wasn't 'smooth'. So I have done quite a lot of reshaping around the front right of the dome, extging around the back, aswell as the top, extending over to the right side and back. Some more filler now which is drying and needs to be sanded still, but I am now much happier with the shape of the dome, and once sanded this time, it should be a case of just fixing any chips, or imperfections. I know I'm never going to get it perfect, and I could easily spend the next 6 years sanding the dome to get it just right

But moving onto the ear pieces. Only put the one together so far (as cutting it all out took aaaaages!) I coated the whole thing in PVA glue, and then lightly sanded just to rough it up a little. I then mixed a very thin mix of my filler, using maybe a 1:1 PVA, Filler mixture. This allowed me to coat the ear piece well It takes 12 hours or so to fully set, but it does sand very well, and I can get detail back later. Said in earlier post I was gonna lookin into casting, if this comes out ok, I probably wont bother. I also put what was left of the mix around the inside of the cheeks, as I mentioned I wanted to cover the fiberglass, aswell as give a little more rigidity. Just a test. If it works out ok, I will consider coating the entire inside of the helmet in it, or just some areas that are a little fin (such as cheeks, and back panels).

Coin slot also looking much better now, and will soon be glued into place. All of my stuff for painting has been ordered, so I would like to maybe start that next week, but who knows.

Magnavis · Feb 16, 2017

I'm going to cautiously say that the dome is DONE! I need to prime it again, aswell as sand through the grades to remove scratches etc...But as for the general shape, I am no much happier. Is it perfect, I suspect far from, but I'm hoping the primer won't reveal anything too dramatic! My experiment with a gloopy mix yesterday didn't have the desired effect, and infact is still a little soft in places. Thats what experimenting is for though I guess. No damage done. Done another coat today over left ear piece, another couple of fill/sand sessions I think before that one is done. Offered it up to the helmet, and it fits relatively well. I did sand the ark down a little as it was too long I found. Once it's at a stage where I think it's ready, I will prime it, and then glue it to the helmet (no plants to make it removable). Will also make it easier to match it up to the helmet more, as I can flll the gap, especially where the ark is, and then get the back through sanding. Bottom of it it's flat yet either, so need to work on that. Still need to assemble other ear piece. I also need to add the turn signals still. Should have done it at beginning, but I forgot. I plant to copy the shape on, and then use a small drill piece to drill away at the section. What I'm hoping wont happen is that drilling it will create a crack in the helmet. It shouldn't really, but it is a slight concern. If you can think of a better way then that, then please let me know....Dent is looking much better now. Not accurate to screen, but then I'm not particularly concerned by that. Paint came in today also. But enough writing, no-one reads it anyway

...PICTURES!