Mandalorian Helmet (Scratch Build)

Whistlingbird · Apr 13, 2020

Update:
The Resin finally set up!
Today I used the Dremel tool and sanded out the inside supports.
I then sanded some more and applied a layer of fiberglass to the inside of the helmet which is drying today.

Frogfreak · Apr 13, 2020

Whistlingbird said:
Update:
The Resin finally set up!
Today I used the Dremel tool and sanded out the inside supports.
I then sanded some more and applied a layer of fiberglass to the inside of the helmet which is drying today.View attachment 188463 View attachment 188464

woohoo! looking great!

droidbait · Apr 13, 2020

Well I'm glad it cured. Praise the sun!

Whistlingbird · Apr 14, 2020

Applied more fiberglass to inside of helmet this morning...
I also sanded and trimmed the fiberglass edges this afternoon...
Still a lot more work to go!

Frogfreak · Apr 14, 2020

Whistlingbird said:
Applied more fiberglass to inside of helmet this morning...
I also sanded and trimmed the fiberglass edges this afternoon...
Still a lot more work to go!View attachment 188483 View attachment 188484 View attachment 188485 View attachment 188486

Awesome! Loving the progress!

Whistlingbird · Apr 16, 2020

Applied more bondo to outside of helmet, smoothing out defects, and sanded like crazy.
Applied black gloss primer to helmet, still have some areas that need to be smoothed out, and more sanding prior to applying the chrome paint
Also working on the inside portion of the helmet which I applied a ledge that will meet the liner, and primed the inside of the helmet.
With all the chemicals used in making the helmet, i.e. Bondo, resin, paint, glue etc. I found a great material to use for the lining that can seal off the helmet from the wearer. The material was found at the local Walmart, Pro-Tuff Outdoor Solid Fabric, it's durable, polyester-faced material and has a PVC backing, waterproof and easy to clean.
I'll be applying it next week.

Frogfreak · Apr 16, 2020

Whistlingbird said:
Applied more bondo to outside of helmet, smoothing out defects, and sanded like crazy.
Applied black gloss primer to helmet, still have some areas that need to be smoothed out, and more sanding prior to applying the chrome paint
Also working on the inside portion of the helmet which I applied a ledge that will meet the liner, and primed the inside of the helmet.
With all the chemicals used in making the helmet, i.e. Bondo, resin, paint, glue etc. I found a great material to use for the lining that can seal off the helmet from the wearer. The material was found at the local Walmart, Pro-Tuff Outdoor Solid Fabric, it's durable, polyester-faced material and has a PVC backing, waterproof and easy to clean.
I'll be applying it next week.
View attachment 188525 View attachment 188526 View attachment 188527 View attachment 188528 View attachment 188529 View attachment 188530 View attachment 188531 View attachment 188532

Looking great!

IntentionalDraw · Apr 19, 2020

Your build has inspired me to try my hand at scratch building a helmet. Keep up the great work!

dboy · Apr 20, 2020

Fantastic!
Very nice that you went through the ordeal of documenting the whole build!

Whistlingbird · Apr 21, 2020

Running behind on my build as I had some other things I had to get done at work.
More Bondo applied today as the primer definitely reveals underlying defects, still a lot more sanding to do... a lot more.
After that I will then apply more black gloss primer spray paint and recheck again for any more defects.
Then will likely start the chrome paint.
Ongoing process...

Whistlingbird · Apr 28, 2020

Fine tuning the mohawk trim, sanded the Bondo again today, and repeated the application of the black gloss spay paint.
Will be planning on applying the chrome paint very soon once I am happy with fixing any more underlying defects.

Sabertooth · Apr 28, 2020

Love the detail in your earpieces mate, can't wait to see it finished up

Whistlingbird · May 5, 2020

More sanding today... Will then reapply black gloss prior to chrome... still checking for underlying defects...

Frogfreak · May 5, 2020

Whistlingbird said:
More sanding today... Will then reapply black gloss prior to chrome... still checking for underlying defects...View attachment 189508 View attachment 189509 View attachment 189510 View attachment 189511 View attachment 189512

That's looking amazing!

Sabertooth · May 6, 2020

Whistlingbird said:
More sanding today... Will then reapply black gloss prior to chrome... still checking for underlying defects...View attachment 189508 View attachment 189509 View attachment 189510 View attachment 189511 View attachment 189512

Hell yeah, can't wait to see it all finished up, what brand will you be using for the chrome?

Whistlingbird · May 7, 2020

I will be using Rust-Oleum 7718830, but I will be applying some heavy weathering afterwards..

Whistlingbird · May 7, 2020

First base coat of chrome applied today...

Whistlingbird · May 10, 2020

Metallic Finish Rub n Buff applied today, polished to a good shine, also still working on weathering, still need to paint ear trim, then it's on to the inside of helmet for lining application, and finally visor assembly, more pics to come!