Need some helmet advice...

Soundwave

Hunter
Hello! I'm quite new here, and just received my helmet for a ROTJ build. After taking everything out, and doing some mock-up assembly I can see that I'm going to have a few problems getting this helmet squared away. My biggest problem right now is the right side of the helmet where the lower ear attaches. This portion of the helmet is bowed, and the ear can't sit flush. Does anyone have any suggestions on how to fill this gap? I'd rather not drop the cash for another dome piece if I can avoid it.

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Still fairly new to this my self but judging by the picture you might be able to remove some of the material off both ends of the ear and make it lay more flat the helmet will still be bowed inward but the gap should be less prominent... just a thought


Sent from my iPhone
 
Still fairly new to this my self but judging by the picture you might be able to remove some of the material off both ends of the ear and make it lay more flat the helmet will still be bowed inward but the gap should be less prominent... just a thought


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This is probably what I would do. I'd scribe the gap line and wear it down on my belt sander, but you could probably use a file and sanding block.
 
This is probably what I would do. I'd scribe the gap line and wear it down on my belt sander, but you could probably use a file and sanding block.

A table top belt sander would be ideal for sure, I've never been a fan of bondo for any project at all! In my opinion removing material from the ear should be less noticeable


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Is there no opportunity to ask the vendor for a helmet that is not flawed? Unless the helmet is resin and likely to be reshaped easily this could end up as a very noticeable fix.
 
Thanks, guys. So, if it's resin I should be able to heat it up with my heat gun and clamp it to something flat and rigid to form it?
 
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A lil bit of heat applied with a couple of clamps seems to be helping. Did it with the resin cast ear to get them to shape up together. Now to let it cool and see if it holds the shape afterwards.


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Could just be me... but that ear looks a bit thick? I'd say you could still take a bit of material off little bit at a time to get a better fit


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I definitely have to agree. After looking at some other helmets for reference the ears could probably stand to lose a 1-1.5 mil or so. The plan is to leave it clamped overnight and see if the side of the helmet held its shape. Then it's time to sand/fill/sand/ then cut and prep for primer.

Btw what's a good cutting wheel to use on a dremel for fiberglass/resin? Should I use a metal cutting wheel or one for wood?
 
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More progress today. Now the ears are installed with the use of Chicago screws that have been countersunk then set with jb weld. Inside urethane washers keep everything nice and snug. Just need the lights and servo kit. Waiting to paint til after I get those items.
 
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