NikNak's SgtFang Progress Thread (PIC Intensive)


NikNak aka

Active Hunter
Hey guys and gals a few months back I purchased a SgtFang bucket as the start of my planned rotj/se Fett. I finally got some time to get started and I snapped a bunch of pictures with my new camera. I know this has been done a hundred times before but I know many of you, like me, love watching progress threads so here goes.

Here's my work space not exactly a workshop but it works:
Theworkspace.jpg


Here's the tools that I used to start the clean up of my helmet:
thetools.jpg


This set of Hobby Files is one of the best things that I purchased. It comes with a 2 flat files 1 square file, 1 round file, 1 semi-elliptical, and 1 fully elliptical. You can find them at Home Depot in the tools section, I highly recommend them:
hobbyfiles.jpg


Remember kids always where your saftey gear:
safetyfirst.jpg

hereswhy.jpg


I made my first cuts use my dremel with a carbon fiber reinforced cutting discs. I went really rough on my first cuts as I was terrified of screwing up. I think it was a good idea to do trimming of large areas and then cleaning up the closer details.
1_FirstCuts.jpg


I then scored the thinner more brittle resin that was left over with my utility knife and was able to just snap it off with my hands:
2_FirstCuts.jpg


I then moved to the top of the t-visor and again cut it out roughly:
3_FirstCuts.jpg


Once the rough cuts where done I got a little bit bolder with my cutting wheel and started cutting some of the excess resin out of the visor:
1_VisorCleanUp.jpg


I used a combination of the cutting wheel and a sanding drum to do more of the clean up.
I then decided to switch to a normal Dremel cutting bit to clean out the narrower parts of the top of the T. I figured it would give me more control and allow me to clean up the detail easier. It worked out ok but unfortunately it got away from me a few times and left me with some areas that needed to be fixed. After the area was mostly cleaned I went back with my hobby files and cleaned the narrower areas up.
2_VisorCleanUp.jpg


Screw up 1:
screwup_1.jpg

Screw up 2:
screwup_2.jpg


After the Visor was cleaned out I decided to start putting filler on the bucket. Here's the raw filler after it being put on the bucket. It's squadron white.
filler1.jpg

filler2.jpg

I was also able to use the filler to fix the areas that I had screwed up:
fixingthescrewup.jpg

After 2 coats of filler I am pretty pleased with how the raised areas are looking:
sanded1.jpg

sanded3.jpg

fixedscrewups.jpg


Here's the bucket almost done with the prep work. All that's left is the (gulp) ketslots. My plan for those is to do a rough cut with the dremel and then finish the clean up with the hobby files.
Almostdonewithprep.jpg


Aside from the ketslots I also need to even out the width of the visor opening from the inside of the bucket so that the tvisor will sit correctly.

I'll add more pics as I have time to update this. It may be a while due to the fact I have to move out of my apartment soon.
 
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Jimmy BufFETT

Well-Known Hunter
Nice work so far. Just gotta question a little off subject because I really wanna know: what on Earth happened to your safety goggles in the second pic of yourself?:lol: Did ya spray yourself?
 

NikNak aka

Active Hunter
No I dont think that I will as this one is gonna be ESB style paintjob. I have an MS3 on the way that will be 100% RotJ so I probbaly will with that one.
 

NikNak aka

Active Hunter
Also, I have a pair of movie accurate ears coming in from Lee(RougeStudios) and Single Seat. So I will have to modify the RF ear to work with the new ear caps. I hope that I do a good job and people can use this as a guide for their mystery helmets.
 

AFettFullofDollars

Well-Known Hunter
No I dont think that I will as this one is gonna be ESB style paintjob. I have an MS3 on the way that will be 100% RotJ so I probbaly will with that one.

Actually the cheek corners are squared on the ESB also. I think the rounded corners were a hold over from the DP 95 that was used as a guide in the sculpting process.
 

goldenrod

Active Hunter
It is a bit nerving when doing cutting. But you did a nice job.
So hows the wife dealing with the kitchen being turned into the shop! LOL!
 

superjedi

Sr Hunter
Also, I have a pair of movie accurate ears coming in from Lee(RougeStudios) and Single Seat. So I will have to modify the RF ear to work with the new ear caps. I hope that I do a good job and people can use this as a guide for their mystery helmets.

Now that is something I'll be very interested to see!

Nice work so far. (y)
 

NikNak aka

Active Hunter
A disaster almost just happened. I was getting ready to go look at apartments and I had my bucket sitting on my bed. When I went to grab my jacket off the bed it knocked the bucket onto the ground right on to the mandible. It made a pretty nasty crack from the corner of the tvisor area to the rear of the bucket. Thank fully I was able to put some CA glue on it right away. I'll putty it up after the CA dries to cover the crack up.
ohno1.jpg

ohno2.jpg

fixing1.jpg

Do you guys think I need to reinforce this any more than just the CA glue and putty?
 
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MandalorFett

Well-Known Hunter
I broke the mandible off my Sgt. Fang too. Be sure to use shims on the inside of the bucket to reinforce the two pieces together. No one sees the inside but you so it doesn't have to be pretty, but it needs to be functional and support the two pieces.

(y)
 
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