Making helmets

So I want to make a buck so I can cast a helmet, I do like my one I made from the templates and I will keep it going as long as I can as its perfect for trooping, that said I want to up the game a little, I did start a brief conversation about this on my ROTJ journal but am moving it here, I need as much input as possible ( I wont say criticism as I hate that word)

So I got this helmet that Target was selling some time ago its kind of ok, there are lots of inaccuracy's on it that if modded could make a useful buck to cast from, I am sure by now everyone is aware of these helmets and the work needed to get it up to a good standard.



I have seen some painted and they look fantastic but I can see they have way more potential.












mods include

Remove visor
Reshape the dent (it's not in the right place but not far off)
Widen visor area and infill visor grove
Cut key slots and make slightly taller
Add the damage, scuffs, and chips
Re-position right ear and move up.
Fill and curve the top of the dome (as it has a flat top)
Re-shape bottom of left ear
widen range finder cap and slit
Make new range finder


These are but a few mods needed as a start, but the end game is to have something that looks correct, is solid and can take a silicone mold for casting.

the top of the dome needed filling out so I have come to a good point where it looks good but could do with a bit take off







it is smooth as marble so dead happy about that. but needs curving inward a bit perhaps??

I think this will be an awesome conversion!! But, I don't think you'll be "allowed" to cast this as it's an existing piece, especially one that belongs to Disney. Even though you have some solid mods and you'll do great on it, I think that still counts as recasting... I could be wrong. Either way very much looking forward to your build!!

Understand the issue on re-casting, I don't like people that buy and re cast. the only way around all this is the fact that almost every part is a little bit wrong as far as I can tell so hopefuly by the end of it it will be outside the spec foe the original and end up with something different... if by then it's still not acceptable I will use dimensions from the finished item and make a buck out of something else.

So the more peoples factual views the better, I want to get this right and not be chased off the farm with pitch forks

To be honest Craig, there are so many great makers out there making lids already and the Rubies is great enough for a budget anyway, I think you'd be far better off casting your Boushh lid which is a work of art. There are so few of them around and supply and demand etc...if you made them available at a decent price I think you'd make a load of cash and without the legal nonsense of recasting

Maybe, I may even fill the dent in and scuff's and do a basic Madno mold, The Boushh helmet was not so bad just took a lot of effort, I have no idea what demand is like for one of them, plus all these new starwars films coming out I fear the classic cos play outfits we see and familiar with will become dated :confused

Silverstalker said:

Maybe, I may even fill the dent in and scuff's and do a basic Madno mold, The Boushh helmet was not so bad just took a lot of effort, I have no idea what demand is like for one of them, plus all these new starwars films coming out I fear the classic cos play outfits we see and familiar with will become dated :confused

Click to expand...

I hope that's not true, and really don't think it will be, especially with the "pre" movies (Han and Fett) scheduled or rumored to be coming out.

Keep in mind that there are people who collect just the helmets as well as some character focus collecters that may be interested in a quality Boushh replica.

Boushh lid maybe:unsure its a tricky helmet to get right the one I have made could do with a bit more time on it. I will still go ahead with this modded Fett lid and cast one even if its just for my self and see if it's something I can do with a quality finish.. It still needs lot's of work I am trying to work out the correct thickness of the visor section at the moment and come up with a good balance as it was before it seems a bit shallow so the visor was cut out widen up a bit and filled smoothed.


If anyone knows the answer to this quastion it would be a great help - The front of the visor where the mandible curves from the top of the cheek round and down to the bottom of the chin? is the leading edge of that a crisp sharp line or is it slightly curved/smooth? I have never been able to tell just from the original pictures? the Target lid has a very smooth curved edge to it looked?