Din Djarin helmet - scratch built, moulded and cast

[DavidF]

Following the success of last year's Boba Fett helmet (thread here), I thought I'd make another helmet, this time Din Djarin's helmet from The Mandalorian. Once again I started with cardboard and created a smooth and accurate sculpt before moulding and casting it in polyeurathene resin.

Here is the final result:

I painted it in Alclad II (107 Chrome for plastic), over gloss black, then coated the helmet with Alclad's aqueous gloss sealer.

I started this project in April 2021.


I downloaded some partial foam helmet templates and started to adjust them for accuracy and size


I reinforced the cardboard with fibreglass and resin, and smoothed the outside with Isopron P-38 (British equivalent of bondo).



It wasn't easy getting the shape right. It took quite a bit of measuring from screenshots and pictures of the original helmet. I quickly realised that I'd made the forehead too rounded and sanded it to a nice flat slope. I then build up the ears, crest and rear vents from cardboard, and smoothed them with filler.


Eventually, after a few months of work, I had a sculpt I was happy with.



Once I'd finished the sculpt, I moulded it in Rebound 25 with a fibreglass jacket, and cast it in Smooth-cast 65D


I cast the ears seperately using the same method.


Here is the first cast of the finished helmet next to the mould and the original sculpt.

 

[B0B4F3TT]

Following the success of last year's Boba Fett helmet (thread here), I thought I'd make another helmet, this time Din Djarin's helmet from The Mandalorian. Once again I started with cardboard and created a smooth and accurate sculpt before moulding and casting it in polyeurathene resin.

Here is the final result:

View attachment 215323
View attachment 215324View attachment 215325View attachment 215326
I painted it in Alclad II (107 Chrome for plastic), over gloss black, then coated the helmet with Alclad's aqueous gloss sealer.

I started this project in April 2021.

View attachment 215328View attachment 215329
I downloaded some partial foam helmet templates and started to adjust them for accuracy and size

View attachment 215331View attachment 215332
I reinforced the cardboard with fibreglass and resin, and smoothed the outside with Isopron P-38 (British equivalent of bondo).


View attachment 215330 View attachment 215333View attachment 215334View attachment 215335View attachment 215336View attachment 215337View attachment 215338
It wasn't easy getting the shape right. It took quite a bit of measuring from screenshots and pictures of the original helmet. I quickly realised that I'd made the forehead too rounded and sanded it to a nice flat slope. I then build up the ears, crest and rear vents from cardboard, and smoothed them with filler.

View attachment 215347View attachment 215348View attachment 215349View attachment 215350
Eventually, after a few months of work, I had a sculpt I was happy with.


View attachment 215339View attachment 215340View attachment 215341View attachment 215342View attachment 215343View attachment 215344
Once I'd finished the sculpt, I moulded it in Rebound 25 with a fibreglass jacket, and cast it in Smooth-cast 65D

View attachment 215345
I cast the ears seperately using the same method.

View attachment 215346
Here is the first cast of the finished helmet next to the mould and the original sculpt.

Thats a really cool post. Im not familiar with casting products so this helps massively. Thanks.

 

[DavidF]

Thanks B0B4F3TT . I'm glad I was able to give you some useful information.

I've just bought myself a 3D printer in the Black Friday sales, so I expect my next helmet project will involve less messing around with moulding and casting! I'm glad to have done it a couple of times though.