Luckily for Ben Burtt (who was a bit overwhelmed by all those features and gadgets), he was helped out by Norman Reynolds, the person who was responsible for drawing the blueprints and supervising the making of the actual suit using concept images of Ralph McQuarrie and Joe Johnston. According to the Star Wars Costumes book he hired Jan(et) Stevens to model the armor, the gauntlets and the helmet, John Mollo to design the soft parts (which were made by Berman and Nathan for both ESB and ROTJ), Brian Archer to do the model of the jetpack with timber and plywood using a mock up that he (Norman Reynolds) made from cardboard and foam core; the suit was assembled by Brian Archer and Nick Allder, with help from George Block (fiberglass parts of the Supertrooper weapons and the right gauntlet plug block) and Bob Dickinson (electronics and flamethrower functionality).
On the brass bolt... I had a problem with my FPH2 ears from Machinecraft in that, there wasn't enough threaded material to compensate for the thickness of the helmet fiberglass... so the brass bolt wouldn't thread into the front plate/range finder stalk cover...
These look flush on the back... with no thickness of helmet material space...???
I do not know about an epoxy one out of the box. Epoxy shrinks around 2% while TC is 0.002 inch per inch (0.2%) (from memory). Maybe you would need to enlarge the platforms on an epoxy one. Anyway, boba87fett could deny or confirm my theory.
I do not know about an epoxy one out of the box. Epoxy shrinks around 2% while TC is 0.002% (from memory). Maybe you would need to enlarge the platforms on an epoxy one. Anyway, boba87fett could deny or confirm my theory.
Very reassuring, also for my own plans, that a less shrunken helmet is going to be the basis. Also props boba87fett for actually ginving real measurements regarding the shrinkage! ANd especiall to also give them in mm for us guys across the pond that have no clue what those strange fractions of inches are