Death Watch Building Armor for Star Wars Celebration 2015 - Now with Night Owl

If anybody hasn't figured it out, I work with Thorssoli (my friend Shawn) in his shop from time to time... While I've never really sold anything through the dented helmet or the RPF, I'm sure he's already figured out a price and shipping costs. It's worth mentioning that while the bike helmet base is narrower, it is also a bit longer from front to back. I have a pretty big head, so I'm hoping this will be a good answer to all of us who don't fit the other helmets. I'll keep everybody posted.
 
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And yet another good day of progress on the helmet. I got the helmet wet sanded with 360 grit paper and waxed in preparation of molding it, and I even got the print coat of silicone mixed up and onto the helmet... I just might be able to get a casting or two out of the mold this weekend. Then again, I have to go see Guardians of the Galaxy this weekend. Either way, enjoy the progress photos:

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Wet Sanded with 360 grit.

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Waxed and prepped for molding.

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Stealing materials from my friend Shawn...

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I'm the guy with the big head... in the front of the picture - as opposed to the guys with big heads in the back of the picture.

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Print coat of silicone is done.

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Ok...so one dumb question...from what I can tell none of the DW grunts have the "turn signals". These would have to be filled in and smoothed to get a 501st approval, right? Or is this for custom Mandos?
 
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You bring up a valid point, and it was discussed at length before I started the build. The short of it resulted in that they would be easier to fill after the fact then to cut them in if we decided that we wanted them.

As to what I am planning to do on my costume, I'm going to have them. The clone wars series uses a very stylized helmet for the Death Watch guys. The critical point for me was that they did show the Jango Fett helmet in one episode and it was the same stylized helmet that the Death Watch guys were using (although it did show the turn signals). As I'm looking to build a Death Watch uniform/armor that looks like it was from one of the movies and not the cartoon, I figure that every movie mandalorian helmet had these, so why wouldn't these ones.

I looked into the 501st requirements a bit as well and it looks like they require animated style helmets. As I'm aiming for a movie style helmet of the animated character, these will not likely qualify for use with the 501st without some modification. While the turn signals will be easy to fill, I shaped the visor very much like the movie helmets and not the animated series. This will not likely be an easy modification. Of course if they include death watch guys in the upcoming Boba Fett movie, I just might be ahead of the game for once.
 
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You bring up a valid point, and it was discussed at length before I started the build. The short of it resulted in that they would be easier to fill after the fact then to cut them in if we decided that we wanted them.

As to what I am planning to do on my costume, I'm going to have them. The clone wars series uses a very stylized helmet for the Death Watch guys. The critical point for me was that they did show the Jango Fett helmet in one episode and it was the same stylized helmet that the Death Watch guys were using (although it did show the turn signals). As I'm looking to build a Death Watch uniform/armor that looks like it was from one of the movies and not the cartoon, I figure that every movie mandalorian helmet had these, so why wouldn't these ones.

I looked into the 501st requirements a bit as well and it looks like they require animated style helmets. As I'm aiming for a movie style helmet of the animated character, these will not likely qualify for use with the 501st without some modification. While the turn signals will be easy to fill, I shaped the visor very much like the movie helmets and not the animated series. This will not likely be an easy modification. Of course if they include death watch guys in the upcoming Boba Fett movie, I just might be ahead of the game for once.

Now that I look at the visor more closely, I see exactly what you mean!

I'm going for 501st clearance on this, so I'll have to mod my existing lid to make it fit my noggin! Looks like a cool project though!
 
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More progress pictures are here! I've got the helmet under rubber now, and the backpack is starting to take shape. Enjoy :)

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The next step will be to make up the fiberglass mother mold.

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Pepakura jet pack is coming together. I'm not sure how I'm going to make copies of this piece. Vacuum formed would be pretty easy, but fiberglass would be stronger. If anybody has experience with each, or a better idea, please let me know.

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Goodluck with the jetpack bro. It, along with the helmet, are turning out really well! I gave up on my jet pack I mentioned earlier... Too hard for me lol. Maybe I can get one commissioned by you haha
 
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More progress pictures are here! I've got the helmet under rubber now, and the backpack is starting to take shape. Enjoy :)

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The next step will be to make up the fiberglass mother mold.

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Pepakura jet pack is coming together. I'm not sure how I'm going to make copies of this piece. Vacuum formed would be pretty easy, but fiberglass would be stronger. If anybody has experience with each, or a better idea, please let me know.

The vaccuform kits are usually done in sections and assembled with resin accessories, so the resin might overall be easier..?
 
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Goodluck with the jetpack bro. It, along with the helmet, are turning out really well! I gave up on my jet pack I mentioned earlier... Too hard for me lol. Maybe I can get one commissioned by you haha
I'm not 100℅ sold on the pep jetpack yet. I may end up using it for measurements ond building one from MDF. If you like the finished one, I'm sure we can work a deal.
 
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Matt's dropping the ball in the update department. It turns out the gooping is essentially complete:
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Registration keys have already been added, but I may decide to be paranoid about not making the mold thick enough and talk him into adding a bit more rubber.
 
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It's been a few days and I figure I would provide an update (pictures may need to be uploaded later as my internet is way slow right now). I got one more layer of silicone added to the helmet mold and made the molds for the ear and range finder. I also saw Guardians of the Galaxy two times and goofed off in a ski boat in Rio Vista... very productive weekend.

and the pictures are here!
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Stealing more silicone from Shawn... (don't tell him)

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Mold Boxes ready to put silicone in.

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Sorry again for lack of pictures... My internet has been something worse than bad in the evenings, but I promise to add the pictures as soon as I can. I got the first half of the fiberglass mother mold done today. My friend Shawn also made some castings of the rangefinder and ear piece while he was casting some other stuff earlier today. It really is my expectation to get a few pulls of the helmet made up this weekend.

And we have more pictures!

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Not all that exciting, just half of the mother mold... My friend Shawn is threatening to finish it tonight and make the first casting without me, but he knows that I know that he has more important projects to work on. Isn't that right Mr. Shawn?

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I got the pictures up from the last few days. I should have the mothermold done tomorrow if all goes well and castings should be coming out this weekend. :)
 
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So my friend Shawn got all ambitious and decided to work on my project a bit (he does this every time he has a real deadline and needs to take a break from whatever that project is). Anyway, he made up the second half of the mother mold and got everything ready to cast last night. I would have probably had two or three casts from the mold already, but my wife insisted that we go watch the new turtle movie tonight. I'm not a fan of Megan Fox, but overall, I liked it... I'd go see Guardians of the Galaxy for a third time, and probably a forth time, before I saw turtles again, but it is definitely worth the matinee price.

Have some pictures: (I told Shawn that these would make him famous)

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Shawn pulling the master from the mold.

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Shawn thinking to himself that this silicone sure looks like the silicone missing from his bucket (don't tell him I took it).

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Master, mold, and mother mold all lined up.

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nice.
looks really advanced and difficult to do. I hope to get into making molds one day and casting helmets. I know you described it already, but i'm not quite clear on the mold-making and filling process.
any way, with more pics i can figure it out. where do you buy the pink silicone stuff?
great work thus far.
i'm excited for more pics!
-Ghost
 
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