New batting helmet bucket

SD68

Active Hunter
This is my first post on the forum and I just want to say how talented the members are. I contacted wizardofflight for his helmet templates and have started my own scratchbuilt ESB Fett helmet. I'm just going to attach the most recent photos of the build. I'm using the batting helmet method which has been used so brilliantly by Kripps and Kibosh. The jpeg is large file and I do have more of the entire construction process. Right now I'm just trying my hand at posting and attaching a file. Any information on the best way to post a jpeg and at what resolutions would be appreciated. I have about 20 more photos of the construction and would like to post them for the forum members input. The photos show the cheeks after installation and first coat of bondo applied. Thanks for all the info and inspiration.

Helmet 23.jpg


Helmet 24.jpg
 

SD68

Active Hunter
Thanks, Superjedi, and I hope to post the rest of the construction photos soon. I need to decrease their file size but more are on the way. As you probably noticed I am using for sale signs for the construction, as well as, the batting helmet.
 

GCNgamer128

Sr Hunter
I LOVE it when I see people build their own buckets, it just makes you feel so much better saying, "I made this." Instead of, "I bought this..."
 

SD68

Active Hunter
Here are some more progress photos. They show the batting helmet cut into quarters and then attached together with strips of for sale sign. Not sure if the for sale signs are sintra or not but they bond well with Pro Weld and are a dream to work with. They score and snap cleaner than ordinary styrene. Gaps were filled with epoxy putty on top of helmet for strength. Then bondo was applied to finalize shape. Minor imperfections were corrected with 3m spot putty. Achieved initial dent shape with a propane torch and a piece of 1" aluminum rod ground to approximate dent shape. Final step was to attach a 1/4" MDF ring with epoxy to bottom of helmet cut to template size. Used this for final putty applications and as a larger surface area to glue the sign helmet pieces to.

Helmet 2.jpg


Helmet 4.jpg


Helmet 5.jpg


Helmet 6.jpg


Helmet 7.jpg
 

Kripps

Active Hunter
Really nice work! Really.....
You gotta be dying right now to finish the ears off and paint ;) .
Keep us posted on the progress.....I love the scratchbuilt stuff.

Josh
 

SD68

Active Hunter
Thanks for the kind words and encouragement. I do have a question for anyone on the forum. What is the proper angle of the upper cheek attachment to the mandibles-does it have the small radius or is it squared off?
I tried to look at the high resolution photos of the reference cd but it is hard to tell. The right side seems to be squared off and the left side seems to be somewhere in between. Any help would be appreciated because I am about to start final sanding of the cheeks and want to get the shape just right.
 

terminal fettler

Active Hunter
SD68 said:
Thanks for the kind words and encouragement. I do have a question for anyone on the forum. What is the proper angle of the upper cheek attachment to the mandibles-does it have the small radius or is it squared off?
I tried to look at the high resolution photos of the reference cd but it is hard to tell. The right side seems to be squared off and the left side seems to be somewhere in between. Any help would be appreciated because I am about to start final sanding of the cheeks and want to get the shape just right.
I looked very hard at the same pics, i'm pretty sure they're squared off. The problem is the paint job distorts their shape, you've also got a tight radius(the upper cheek) meeting a right angle(the mandibles) when i sanded these two surfaces to meet each other, they natrually want to form a curve, creating a tight radius at this junction is tricky. Once i achieved this , to me it looked accurate. The cheek/mandible area is where i spent most of my time on my scratchbuild and i think its the trickiest part to get right....Great helmet by the way,can't wait to see the paint starting to go on....
 

SD68

Active Hunter
More photos of the construction. The dome is primered and ready for the dent to be refined and accurized. The next few show the large helmet pieces which were made by forming them to shape, screwing together in the back, and then submerging them in boiling water for 5 minutes to retain their shape. I was surprised how well this technique worked for such large pieces.
With Alan doing all of the hard work for us the pieces went on without a hitch with epoxy and Pro Weld. The flair matches perfectly with the templates. As said here before, Alan is the Man! From there I pieced in the cheeks with four pieces using the same boiling water to form them. Now it is on to the back of the helmet and the keyslots. I will keep you posted on my progress. Once again this forum is awesome and the members comments will allow me to make the most accurate helmet possible.

Helmet 13.jpg


Helmet 10.jpg


Helmet 14.jpg


Helmet 15.jpg


Helmet 17.jpg


Helmet 18.jpg


Helmet 20.jpg


Helmet 21.jpg
 

SD68

Active Hunter
It has been over a three week period to reach the point I am at. I probably managed about 8 hours a week of work time on it. The dome was obviously the most time consuming part. I would say it took probably 2/3 of the total time just to get the curves accurate and the dent and arrows in the proper locations. Once the dome matched the templates the rest followed relatively quick. I'm sure things will slow as I add the detail pieces and get it ready for paint. I love the construction portion but I can't wait to start the finish process. Patience now is the key. Terminal, your thread is awesome and I can only hope mine can approach yours in quality of build and finish.

Yes, they are for sale by owner signs. I would say approximately 18"x24".
 

terminal fettler

Active Hunter
SD68 said:
It has been over a three week period to reach the point I am at. I probably managed about 8 hours a week of work time on it. The dome was obviously the most time consuming part. I would say it took probably 2/3 of the total time just to get the curves accurate and the dent and arrows in the proper locations. Once the dome matched the templates the rest followed relatively quick. I'm sure things will slow as I add the detail pieces and get it ready for paint. I love the construction portion but I can't wait to start the finish process. Patience now is the key. Terminal, your thread is awesome and I can only hope mine can approach yours in quality of build and finish.

Yes, they are for sale by owner signs. I would say approximately 18"x24".
3 weeks! I just feel like i've wasted 4 months!( and there are details i know i'm just going to end up putting right:facepalm ) By the way, have you started on the 'ear' pieces yet?
 

SD68

Active Hunter
I have got a long way to go and like I said I will probably slow to a snails pace to get the details right. I haven't started the ear pieces yet. Still trying to figure out how I want to create the angle. Either by forming the plastic or just body filler and sanding to match the templates.
 

wizardofflight

Well-Known Hunter
That is a great looking bucket you've got going there. You've done a fantastic job. Thanks for posting the in progress shot, I always like seeing how folks put things together.

I actually went out this weekend and picked up a batting helmet and some "For Sale" signs. You've inspired me to finally build my own bucket.

Thank you for getting me moving again on this project.

Great job

Alan
 
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