IXMandalorianXI's First Scratch Build: Step 2: Outlining a Plan

[IXMandalorianXI]

This thread will chronicle my first attempt at building a prop, and my first attempt at scratch-building a Boba Fett helmet. As I've researched threads and builds, watched videos, and gained a peak at the world and community of serious costume and prop creation, I am both inspired and intimidated at the project I am committing myself too. I am not an artist, and I am not experienced, but that doesn't discourage me. The Fett helmet is one of the more complicated projects out there, and a lot of much more skilled than I crafters have put hours of work into their projects. I am determined to see this project through, even if it comes out horrendous. This thread will serve as a record of my first scratch build.

STEP 1: This Post: Choosing my Material
STEP 2: http://www.thedentedhelmet.com/f23/...build-step-2-outlining-plan-53319/#post668323 : Outlining a Plan and Gathering Supplies


9/25/15
The first step before I even begin building my helmet is to decide what material I want to make it out of. I want a material that will last, be durable, look nice, and be able to obtain and manipulate without fancy tools beyond what I can get at a hardware store. To that end, after a bit of research, I've narrowed my options down to two:

Sintra
or
Cardboard

-I've seen some fantastic cardboard builds, specifically looking at antman and rafalfett's tutorial threads.
-I have been unable to find a good Sintra tutorial, but it consistently pops up as a favorite on the board. Sintra sells decently cheap at my Home Depot. A 10in x 14in 3mm for 31 dollars (also there's a ton of sign shops near me that might have scraps) and that's specifically for a printed sign. I might be able to buy blank white for cheaper. From what I've read, with some X-acto blades/box cutters, a heat gun, and some straight edge rules (and a dremel tool for extra) all of which are decently cheap, I can manipulate, and bend the SIntra to my will. I also already have a charcoal filter mask I can use to combat the fumes from the pvc. As I have no found an amazing tutorial yet for the Sintra, I'm hesitant because I am unsure what templates to use, and how to properly guage the curvature and shapes I create. I am also unsure how to craft some of the smaller and more detailed parts of the helmet with Sintra.

EDIT: After doing some more research I figured out why I could not find Sintra tutorials.
http://www.thedentedhelmet.com/f34/custom-helmet-sintra-3216/
Sintra it appears is decent for armor, but the helmet, specifically the dome could cause problems. While it doesn't seem impossible, it seems like something a lot of scratch builders have decided to not bother with. That being said, some other sources seem to indicate it can be done, even the dome.

I really WANT to use Sintra, but I'm nervous as I am very unfamiliar with it.

So this is step 1, before I advance, or gather supplies, I have to choose my material. Casting is a little too advance for me right now, so cardboard and sintra seem like a great starting place. Please give me your opinions on Cardboard vs. Sintra, If you have any particular tutorials or templates you swear by, and any other advice you can offer. As I advance in m progress, I will update this first post with any new questions, and as I progress, I will post pictures for your viewing pleasure.

I appreciate any an all advice, stories, and comments.

Thank you!

 

[ToEleven]

I've used 2mm/.08" Sintra on my last 2 helmet builds and cardboard on my 1st. I have to say that sintra is much easier to work with by far in my opinion.

Sintra is basically a thermoplastic so it bends with heat. A hairdryer will do the trick. I've used a heat gun with it too, but...keep in mind that sintra will hit a point where it shrinks and is basically useless. I've ruined many dome pieces this way.

It's much easier to cut than cardboard. It's also not as stiff so you don't have the bending issues.

Use a good quality super glue/CA glue. I find that the Krazy Glue liquid is great. It bonds instantly, but if you make a mess with it then you have to go back and hold for 20 seconds or so to get a bond. With cardboard be prepared to do a lot of clamping and waiting.

You will need to catch a fiberglass tut on youtube because you will want to fiberglass the interior if you plan on wearing it much. It's easy and smelly.

That's my 2 cents. If you need to know anything else just ask. I've done everything the wrong way at least once.

 

[IXMandalorianXI]

I've used 2mm/.08" Sintra on my last 2 helmet builds and cardboard on my 1st. I have to say that sintra is much easier to work with by far in my opinion.

Sintra is basically a thermoplastic so it bends with heat. A hairdryer will do the trick. I've used a heat gun with it too, but...keep in mind that sintra will hit a point where it shrinks and is basically useless. I've ruined many dome pieces this way.

It's much easier to cut than cardboard. It's also not as stiff so you don't have the bending issues.

Use a good quality super glue/CA glue. I find that the Krazy Glue liquid is great. It bonds instantly, but if you make a mess with it then you have to go back and hold for 20 seconds or so to get a bond. With cardboard be prepared to do a lot of clamping and waiting.

You will need to catch a fiberglass tut on youtube because you will want to fiberglass the interior if you plan on wearing it much. It's easy and smelly.

That's my 2 cents. If you need to know anything else just ask. I've done everything the wrong way at least once.

I appreciate the reply, I'm glad someone else has made a Sintra helmet with happy results. A few questions:

What is CA Glue?
Also can you expand on the fiber glass tutorial? Why would I need that if I plan on wearing it?

 

[ToEleven]

CA glue is basically super glue. This site gives a good explanation. CA Glue from Satellite City Instant Glues- Cyanoacrylate Glue

As far as fiber glassing goes, the helmet is not very durable on it's own. That can actually be your own call though as to whether you think it is or not. My 2 sintra helmets were scaled down a bit for my kids, so i knew they would be rough on them, so I layered in the fiberglass on the interior. I also coated the outside with fiberglass resin before my final sand and paint. The resin soaks into fiberglass matting or cloth material (for the inside) and will be hard as a rock when it dries. This should give you the general idea.

 

[IXMandalorianXI]

Thank you for the info, I never even knew about fiber-glassing the inside of the helmet, and originally thought I didn't need to fiberglass resin the outside because that was for a different style of crafting the helmet. However that makes a lot of sense as I watch the video. I'm definitely using Sintra, it will be a unique experience and hopefully produce a quality helmet.

So, just to understand your process, specifically with Sintra vs some of the cardboard tutorials, you:

-Created initial helmet with Sintra
-Fiber-glassed the inside (Resin --> Cloth/Mat --> Resin)
-Fiber glass resined the outside.


9/26/15
With that being said, I believe I am ready to move on to Step 2: Outlining a Plan and Gathering Supplies.

For this step, the first thing I want to do is outline the future steps and processes I need to go through, so I can be prepared for them ahead of time. Please correct me if I am missing any crucial or important steps, or if any steps are out of order. I know it seems like I'm breaking this down bareny style, but it's meant to serve as a guide to myself, so I can reference this thread throughout the project and be confident that I am proceeding correctly. Please note that I am NOT INCLUDING painting in my outline because I consider that a beast of a project on it's own. I am also not including the T-Visor installation because the actual shaping and crafting of the base helmet is what worries me the most.


Step 2: Outline a Plan and Gather Supplies that I will need for the duration of this project
Step 3: Determine the Template I will use and create a paper model in order to properly gunge size and scale
Step 4: Following a Template, construct a Sintra helmet, a base helmet where the seams are showing and some imperfections are visible. The dent should be integrated into the initial Sintra design
Step 5: Apply Fiber Glass Resin to the outside of the helmet in order to strengthen the helmet
Step 6: Apply a Fiber Glass Resin-->Fiber Glass Cloth/Mat-->Fiber Glass Resin to the inside of the helmet to strengthen the helmet
Step 7: Apply Bondo to the outside of the helmet. This is to seal and fill in the gaps and visible seams specifically around the dome, and cheeks, and I assume, the RF Stalk which will be comprised of 3 or 4 layers.
Step 8: Sand the helmet until smooth and round in all the right places

Also, I want to use the Zip Zap micro RC Range Finder modification on the RF Stalk, and I want to have blinking LED lights on the RF itself. At what point during the the helmet construction should I do that, or I guess start to take considerations for that. I assume that while constructing the stalk, I'll be following one of the many tutorials that explain how the wire the inside, then after the helmet it complete, I'll attach what needs to be attached to the ends of the wires on the inside of the helmet. I would think that based on the tutorial, I could construct the RF Stalk and RF itself as seperate entities and then attach the RF stalk as a final product.


I also need to create a shopping list of tools and supplies I will need. I have a very basic toolbox with very basic tools, so this list will be decently...expansive (read: expensive.) Again, please note anything I've missed, or need to add or don't need


Tools:
For general construction manipulation of material
--Basic tools, screw drivers, glue gun, pencils, markers, etc
--Cutting board, probably a larger one
--Some sort of workspace table
--X-Acto Blades
--Box Cutters
--Scissors
--Assorted knives/blades
--Dremel?? Do I need this for Sintra?
--Heat Gun (will a hair dryer suffice?) Is this the best way to mold Sintra?
--CA Glue/Krazy Glue/Some sort of very strong adhesive
--Paint Brush, Medium for paining Resin
--Wooden paint dipper/spreader for the Bondo
--A respirator, charcoal filter mask for both the Sintra fumes, and the Fiber Glass Resin fumes
--Gloves
--A Sanding block or Sandpaper (What grain do you recommend?)
--Duct Tape and Clamps to keep the Sintra in place while the shape hardens after heating

Materials instrumental in helmet creation
Paper
--For the test model
Cardboard
--For creating shape templates to mold the Sintra around
Sintra
--Either Home Depot, or see if local Sign Stores have scraps I can procure for cheap
Fiber Glass Resin (Bondo Brand?)
Fiber Glass Mat/Cloth
Bondo

Random Parts
--My old Zip Zap RC car and controller
--A basic circuit board with blinking LED lights for the RF

Anything I'm seriously missing?

As always, any and all help, advice, criticism, etc is