Junior Jango Helmet scratch build WIP

[ToEleven]

I'm currently working on a Jango Fett Scratch build for my son. After finishing Boba at a 92% scale for my older son, the younger was perturbed (rightly so) about not also having his own awesome mando helmet, so I decided to make him Jango (because I'm crazy and hate my free time).

I started with Rafalfett's v1 templates, foamcore, sintra, cheap bondo fiberglass resin, and an el cheapo silicone caulk mold I made for the dome portion.


By the way this guy has a pretty good tut on making the mold. ...and says "actually"... a LOT. https://youtu.be/tBClhbrGR7w
It's a cheap way around dropping a bunch of money for making a 1 off mold...I can't say I'd do it again though. I managed to make it work, but I got no where near the results this guy did in his videos.


I have 2 layers of fiberglass in the dome...it will take a basball bat I'm pretty sure.



...and where I am currently.



I had to modify the key-slot configuration to match the Jango with a little more spacing....and the back-bottom portion of the outer-cheeks had to be widened a little. The dark stuff inside the helmet is Bondo Glass, which is thick resin premixed with fibers. I use it to give extra support to the stress points before I lay the inner fiberglass. I also JB-welded my T-nuts in beforehand so I could use the bondo glass to help reinforce them.

 

[Artakha]

Coming along nicely!

 

[ToEleven]

Here are my CNC'd ears. I use hard maple because it happens to be what I have available. The programs are from RafalFett's (rafalworks) 3d warehouse models. I sized them down and moved the top and bottom right ear into one piece, since the Jango helmet is nearly connected anyway.





Rustoleum primer has been giving me a bad skin reaction from the overspray and fumes, so I tried to use some Valspar spray paint as primer...let me just say DO NOT USE THIS CRAP. It would not cure and I had to use Naptha to get it all off...plus a ton of sanding. It says on the can for wood/metal/plastic, but no. It just wouldn't cure.

Hear are some pictures I took before tearfully removing the paint.




Meanwhile I donned my hoodie, respirator and re-primed with good ole Rustoleum.




Finally after much wet-sanding I have some Rub-n-Buff on the back panels. I've never used this stuff...it was really fun to see it shine up!

 

[5326Commcando]

Valspar is garbage from everything I've experienced. Unless you rub it down with wire wool prior to your next paint app. Otherwise it leaves a film that will only peel.

Sent from my LG-D851

 

[Artakha]

Looking very nice. Keep it up!

 

[ToEleven]

I sprayed Rustoleum Royal Blue and Krylon Ocean Blue for the dark and light blues plus some rub-n-buff. This is right after removing the masking so I haven't done any touch-up to the paint or rub-n-buff yet.

 

[ToEleven]

Rangefinder...





Here is the finished Junior Jango Fett along side his brother PP1 Boba Fett! I have my WIP over here--> http://www.thedentedhelmet.com/f23/toeleven-junior-fett-scratch-build-wip-52997/




I have to say that I've learned so much during the process of building these...which would have never happened without the members of this forum! The problem I have now is I want to build another because I know I can improve on the last one!

 

[googoogaga]

SO COOL!!!!

 

[ToEleven]

Thanks! I appreciate it!

 

[xanthis02]

I agree what they said awesome work