bmx potty + filler = helmet?

[evan4218]

Just looking at the picture on the right Evan, its the colour within the silver, not around it i'm having trouble with, is this what you're referring to? I 'm seeing this as "bluish" still

Your correct about that, I use a flint grey. Its a very light greay with a hint of blue in it.

Really the effect that I think is acchived with this color is to give blemishes to that larger sliver cluster on the back. Gives some detail and even some contrast to the silver.

I think as long as its not too blue your golden!

 

[sithlord23]

I am just reading this thread for the first time! Wow. That is an amazing bucket, and an even cooler journey towards completion, that you've shown us.:cheers

 

[Elofsson]

I just have to say that that is one great looking helmet bro!Are you gonna make a Jango to? That would be super cool!

 

[SD68]

TF, on the left earpiece, is the small strip in the middle recessed and if so how much did you recess it? I am starting my ear pieces and need to know this little detail. In most of the photos it appears to be recessed but I would like to be sure. Any help would be appreciated. Are you going to move on to the ROTJ or are you going to weather the ESB first. I am really interested in your weathering techniques you mentioned earlier such as tar and coffee. By the way the helmet looks absolutely incredible. I can't wait to see what you do with the other version.

 

[terminal fettler]

Hi SD, the strip on the L/H ear is approx. 2.5mm wide and 2.5mm deep. I'm going to weather this helmet first ; i'm interested in seeing how its going to work too!

 

[webchief]

Simply gorgeous! You are a master!

 

[DarthVader1]

:love

(distorted speaking)

EHWWEHWEWHEWEHEWWEH !!!!....(trying to pick up my mandible from the ground)


OK, let's start planning an infiltration to his house and steal this beauty...BLACK-OPS/MISSION IMPOSSIBLE STYLE!

Fantastic work! I BOW BEFORE YOU, LORD ALMIGHTY OF THE SCRATCHBUILT HELMETS !!!

Robert

 

[Indy Solo]

Beautiful bucket, TF. Very impressive work!

 

[xeco]

Finally got round to moulding the potty! Heres a pic of the skin mould sat in its two piece jacket, the T20 silicone rubber just peeled straight off the master leaving it intact, phew. (i had visions of having to break it up ) Luckily the T20 is very elastic In 48 hours time (when its properly cured) i should have a cold cast aluminium bucket...........to start painting

Yeah lovely work. (I'll not gush ) I'm about to work a custom helm design and was going to mold cast as well, but I needed to see someone else's work for a mental reference. Thanks so much for the rundown of your process.

I do have a question, I see you have a rubber mold above, within what looks like plaster (or harder casting stone). I would love to know how you did it, in specific, in which order did you cast the silicon, stone and did you use a frame for the stone?

Also.. powered aluminium + gel-coat (+ Fibreglass powder?) I was wondering if you added fibreglass powder to the gel mix for strength. I had occurred to me that it might avoid chipping of the primary layer of gel, though.. the aluminium powder.. I wonder if this has a similar effect.

Finally, when you say 'fibreglass tissue', could you specify what weave and weight you used? It would be a great help.

Again, thank you very much.
-Xeco

 

[xeco]

Oh.. yah.. one more thing. Can you let me know EXACTLY what micron you bought as far as the aluminum powder goes. Also was it atomized? or Flake?

How much would you say you used overall having made 2 helmets and several other parts.

The more i read about powdered aluminum.. the more I know I'll be mixing it outdoors lest I set my home on fire. *shudder* Metal fires are just insanely hot and I'd be totally knackered if it did catch fire. I assume you had no trouble or concerns about the resin heating with the aluminum powder within? (yes.. I know I seem like I'm nuts at this point).

Also.. what resin fillers did you use other than the metal powder?

-Xeco

 

[terminal fettler]

Its a very simple process , your master is first painted over with silicone rubber, in the case of my mould, i used a one piece 'skin mould'. This is ok as long as there are no serious undercuts. This leaves no issues with lining up a two piece rubber mould. The jacket is casting plaster reinforced with scrim, its two piece with a join running front to back. I would recommend finding a publication on these processes, or better still, a sculpting supply shop, they will offer the best advice. Also start with casting something small and get the feel for the process as these materials can prove expensive!

 

[xeco]

Ahhh very cool, Good point about the undercuts, Hmm. I do actually have a book on the subject and come from an artistic family so no trouble there but there is no substiute for visual referance and asking lots of annoying questions, heh. As far as I'm concerned you can do no wrong in my eyes. You clearly know your stuff. Lots of talent, you.

And what of the metal powder? How did you avoid death by kaboom? All the blaring warnings I've read make the stuff sound like old nitro-gycerin.

Did you buy a lot of powder aluminum? or did a small amount suffice?

-Xeco :zam

 

[terminal fettler]

You're quite right, under certain conditions, aluminium in powder form, can be very reactive (as can custard powder) but you've just got to be sensible when handling the stuff. The quantity of powder to resin is the key to the best finish; i've found if you load in the powder gradually, it will turn from a smooth mix to then becoming 'grainy' i.e. you start to see some powdery texture. This is the ideal mix.

 

[xeco]

Oh excelent.. so you did'nt lose any limbs and it doesn't sound as if you went berserk moving it from canister to resin.

Can you tell me what sort of powder size you used? I'm aware it comes in a variety of granular size and to be somewhat consistant can I ask, what size it was? I'd like to get the same.

Also, did you add any other fillers to the resin aside from the aluminum?

-Xeco:zam

 

[terminal fettler]

Oh excelent.. so you did'nt lose any limbs and it doesn't sound as if you went berserk moving it from canister to resin.

Can you tell me what sort of powder size you used? I'm aware it comes in a variety of granular size and to be somewhat consistant can I ask, what size it was? I'd like to get the same.

Also, did you add any other fillers to the resin aside from the aluminum?

-Xeco:zam

Last time i counted i still had... oh, thats not right. DON'T ORDER THE LOBSTER!
Again; you do have to be carefull using these materials.
The powder size is not specified , although it is definately a fine powder and not granular( if that is any help at all, probably not)
i just used alu. powder and resin, specifically GP polyester resin which is more efficient at holding fillers...

 

[xeco]

Last time i counted i still had... oh, thats not right. DON'T ORDER THE LOBSTER!
Again; you do have to be carefull using these materials.
The powder size is not specified , although it is definately a fine powder and not granular( if that is any help at all, probably not)
i just used alu. powder and resin, specifically GP polyester resin which is more efficient at holding fillers...

GP, is that a UK company? I'm in the states. Is it possible that you could reference the phone numbers, addresses and or web addresses of the companies you bought from? That would sort me right out! Cheers! :love

(edit) Oh what I'm seeing is "NORPOL GP (gelcoat primer)" So you used Gel-coat exclusively? GP stands for General Purpose? On another page I read it as: General Purpose (GP) Unsaturated Polyester Resin Copolymerization of Unsaturated Polyester Alkyds with Monomers

-Xeco:zam

 

[terminal fettler]

GP stands for General Purpose, as apposed to, err...Gel Coat resin (not suitable for metal fillers, and there were some others , but it starts to get boring ) Alec Tarranti in the uk is a great source of all this stuff, us wise i'm not so sure. So tell us about this custom helmet then... zam ?)

 

[xeco]

So tell us about this custom helmet then... zam ?)

Ahh that's what I thought, thanks much.

As far as the custom, nope, not Zam. All you Fetts should know the name, Sintas Vel . I've yet to find a good image of her helmeted so, I'm forced to improvise. I'm going to aim for something that takes elements from The Mandolorian, Stormtrooper, and then some of my own design. It's a tricky thing making something from scratch and having it get that Star Wars feel so, I'm going to have a chalenge. on my hands. I did'nt want it to look anything like stuff that had been done. If I was going to do Ailyn Vel I could just do Fett armor and be done with it but.. Sintas is more of a mystery and I thought she would be a lot more fun.

-Xeco :zam

 

[terminal fettler]

It would be nice to see some concept drawings ( or etchings ) although i've never heard of that character; my next project is probably a custom piece.

 

[xeco]

It would be nice to see some concept drawings ( or etchings ) although i've never heard of that character; my next project is probably a custom piece.

Allow me to enlighten you!

http://starwars.wikia.com/wiki/Sintas - Here's the meatiest link on her on the net. She's pictured unarmored here. Well.. not helmeted in any case and very little armor. Seems a foolish way to go about hunting scum so, I'm betting she must have armored up at some point, I might be dodging canon, but, if I remove the bucket, I'm canon again, ha ha.

http://encyclopedia.thefreedictionary.com/Sintas+Vel - This one I have yet to verify but I know she's killed 16 years after her daughter's birth, but from what I'm aware of, Asajj Ventress heads far far away from the core of the galaxy before the events of Ep 3. I'm still doing research, so this link may or may not be true.

Once I get the final design I want the helm to look like, I'll post it. I promise.

-Xeco