Elstree Precision Co Ltd Hero Metal Ears Project

[KaanE]

Would this be correct?

263.525 mm

249.2375 mm

For the ESB Hero, yes, If maths are not wrong.

 

[boba87fett]

I don't think the ESB Hero has been measured with super accurate digital calipers. If it has, I don't have those measurements. As long as you converted the inches to mm correctly, then that should be accurate.

 

[RamSkirata]

Us metric people trying to make sense of those strange fractions is NOT funny

 

[Strider]

New helmet has landed in the UK and is out for delivery. This helmet was cast in TC 1630 with fiberglass in June of 2020 and has the following measurements:

Length: 10 4/16" (-2/16" or -3mm from the ESB Hero)

Width: 9 3/4" (-1/16" or -1.5mm from the ESB Hero)

This helmet has significantly less shrinkage than the first helmet that was sent to Elstree, which was cast in gelcoat resin with fiberglass.

Is this measured from the outside or the inside?

 

[KaanE]

Pretty sure it's from the outside. They inside will vary because of the thickness of the fiberglas and the gelcoat.

 

[Strider]

Pretty sure it's from the outside. They inside will vary because of the thickness of the fiberglas and the gelcoat.

Ah yes, of course. Thanks!

 

[mickxc]

Is it possible to create a pic where these measurements should be taken? Is length from back to front of visor when the cast is sitting flat? What is the measurement for height? Is width the farthest most points of the casting at the ears? Assume ears are excluded?
Who took measurements of the original & when? Are they very reliable?
Thanks in advance

 

[RafalFett]

Is it possible to create a pic where these measurements should be taken? Is length from back to front of visor when the cast is sitting flat?

Usually from back to front means from the outside of the rear keyhole to the outside of the T-visor's bottom line (from point 3 to 4). My measurement is 265 mm.

What is the measurement for height?

The height is a bit harder to measure, but you'll have to use a flat object (like a ruler) to position it flat under the ears then measure from the center- inside of the dome to the ruler (from point 1 to 2). My measurement here is around 260 mm.

Is width the farthest most points of the casting at the ears? Assume ears are excluded?

Usually without the ears and is measured from the lower corner of each cheek (along line 6). I got here 247 mm.

Who took measurements of the original & when? Are they very reliable?
Thanks in advance

The originals were measured several time (PP3 by Master Replicas, ESB by eFX and Anovos), but these measurements are not publicly known (no, I don't know them... yet).

 

[boba87fett]

Is this measured from the outside or the inside?

Outside to outside

ESB Hero Length: 10 6/16"

ESB Hero Width: 9 13/16"

 

[boba87fett]

Is it possible to create a pic where these measurements should be taken? Is length from back to front of visor when the cast is sitting flat? What is the measurement for height? Is width the farthest most points of the casting at the ears? Assume ears are excluded?
Who took measurements of the original & when? Are they very reliable?
Thanks in advance

Ears are excluded. The length and width that have been provided to me are the length and width of the ESB Hero. As with just about everything related to the ESB Hero these days - it reportedly goes back to the EFX molding in 2012. The G1, G2 and lossless G3's out in the wild reflect these measurements. This is generally how helmets are measured for length and width. Below is a photo of a raw G4 Hero, which suffers some slight shrinkage in length.

 

[mickxc]

Great info. Thanks for sharing

 

[KaanE]

boba87, any update on ears? Did he got the low shrink helmet to work with? When do you think the production is going to start? Ia he going to modify something from the proto ears?

 

[boba87fett]

boba87, any update on ears? Did he got the low shrink helmet to work with? When do you think the production is going to start? Ia he going to modify something from the proto ears?

John is on a vacation this week, but he did received the less shrinkage G4 last week and got to work. The left ear is good to go. The right ear needs to be lengthened slightly. He should have everything he needs to move forward next week.

Just a reminder, this process is going to take time. Even once production starts, Id imagine he will only be able to crank out a couple or more per month because they’re made by John and mostly by hand.

Anyone wanting metal ears ASAP should order MCR ears or see what RS Props will have to offer soon.

 

[KaanE]

I'm not in a hurry but I never get tired seeing pictures of these!

 

[RamSkirata]

John is on a vacation this week, but he did received the less shrinkage G4 last week and got to work. The left ear is good to go. The right ear needs to be lengthened slightly. He should have everything he needs to move forward next week.

Just a reminder, this process is going to take time. Even once production starts, Id imagine he will only be able to crank out a couple or more per month because they’re made by John and mostly by hand.

Anyone wanting metal ears ASAP should order MCR ears or see what RS Props will have to offer soon.

Ill wait. I dont even have a helmet yet. I just want these because of what they are and because of the wonderful effort put into them.

 

[boba87fett]

Here are some updates from John a couple weeks ago.

The rangefinder stalks were all drilled in one go and from only one end (top down). Pretty impressive.

And another update from last week. John has been working on re-drawing the final "original drawings" on the proper draftsman's paper while on vacation.

 

[RamSkirata]

Here are some updates from John a couple weeks ago.

The rangefinder stalks were all drilled in one go and from only one end (top down). Pretty impressive.

View attachment 196099

And another update from last week. John has been working on re-drawing the final "original drawings" on the proper draftsman's paper while on vacation.

View attachment 196100

View attachment 196101

Thanks for the update! Stuff like that just takes time (the drawing and the ear-making), especially since it is his free time. Seeing a tiniy bit of progress is much appretiated nonetheless! THis project is just amazing!

Also, whereever John spent his vacation is just beautiful!

 

[boba87fett]

Received the Dentless Supertrooper helmet for John today. Did a preliminary trimming and wet sanded it. Hoping to get more done tomorrow. Will be sending it to him painted white with a gloss clear coat. He will be installing the visor, borden, rangefinder assembly, ears and MQ-1.

 

[boba87fett]

Well my part of the Elstree Precision Co Ltd Dentless Supertrooper helmet build is complete. Time to ship it to John and let him get their metal ears and the other components fitted.

I learned several lessons prepping this lid. Proved more challenging than I thought it would. Not perfect, but I’m happy with it. The helmet itself is fantastic and well built.

Borden and visor are temporarily taped in. John will he installing them similar to how the originals were installed.

 

[RafalFett]

It looks great, Steven! The only downside is the ESB style right upper ear platform, where the front section is not on level with the lower ear platform.