General ROTJ costume build (conversion from SE)

[tennantlim]

Credits to Fett4Real for pointing out my discrepancies and RafalFett's invaluable templates and stencils. Took my dremel and triangle file to the bucket today and ruined it some more.

 

[hvacdon]

Nice ruining there T !!

 

[tennantlim]

Nice ruining there T !!

Thanks!

 

[tennantlim]

Ripped a liner off a cheap worker's helmet and installed into my bucket. Stuck a couple of screws into the bucket with 2-part epoxy, drilled holes in the liner catches, and bolted them on. A foam pad is stuck onto the top of the dome to cushion the top of my head. Fits extremely well, and it's adjustable and removable if necessary. I will be installing a 3-fan set for optimal ventilation and to prevent the visor from fogging up.

 

[tennantlim]

I added cheek pads to keep the bucket in position and prevent me from appearing like a bobblehead. Now the bucket fits like a motorcycle helmet.

Took the helmet out for a spin at yesterday's troop.

The lack of air circulation caused my head to overheat quickly, leading to a massive headache, and my visor to fog up. I had already ordered a 3-fan kit from Singapore but I won't receive it for a while, so I transferred the dual fan kit from my SE helmet to use in the meantime.

One fan drives air in from the rear.

The other one blows across the visor so it won't fog up.

When the 3-fan kit arrives, a third fan will drive hot air out the rear.

 

[tennantlim]

Received the final piece of the ROTJ puzzle; horsehair braids from woodman!

Also received a couple of awesome upgrades from MachineCraft

And finally, a triple fan kit from a vendor in Singapore.

The priority is to attach the braids to my vest and submit for 501st Legion approval. The jetpack vents and gauntlet nozzles installations will have to wait until my schedule frees up in 2 weeks.

 

[TheZeroEffect]

Beautiful work so far, I’m loving the bucket

 

[tennantlim]

Beautiful work so far, I’m loving the bucket

Thanks man

 

[tennantlim]

My batninja neck seal arrived today! It's so beautiful and I'm going to hate weathering it. I may get it sewn onto my flightsuit eventually.

Installed my fans in a configuration that I think optimizes airflow within the helmet. If anyone has better suggestions, please chime in!
Fresh air is driven into the helmet from the rear.

One blows across the visor to prevent fogging.

And finally, one pushes out warm air on the other side.

 

[hvacdon]

Helmet looks great !! You've done a really good job thinking about the air flows and your thought process to remedy the downfalls of the helmet. Not very many folks would go to the trouble to analyze this and come up with a solution as you have done. You might want to move your hot air exhaust fan, rolled down toward the back and moved down a little. Depending on the CFM of the fan, it should pull warmed air from that entire side of the helmet when it's being exhausted.
The reason for moving it down is to prevent the airflow from hitting your face or anything else and causing turbulent air movement before leaving the helmet. I believe rolling the discharge angled back slightly will
move the exhausted air away from you and dissipating better. In case you were standing still, it would prevent the discharged air from migrating back toward your helmet. I hope that helps, that's my official HVAC opinion !!

 

[TheZeroEffect]

You could alway attach an outflow pipe to the exhaust fan to extend its discharge to the rim of the bucket, that way you could put the fan higher if needed.

 

[tennantlim]

Helmet looks great !! You've done a really good job thinking about the air flows and your thought process to remedy the downfalls of the helmet. Not very many folks would go to the trouble to analyze this and come up with a solution as you have done. You might want to move your hot air exhaust fan, rolled down toward the back and moved down a little. Depending on the CFM of the fan, it should pull warmed air from that entire side of the helmet when it's being exhausted.
The reason for moving it down is to prevent the airflow from hitting your face or anything else and causing turbulent air movement before leaving the helmet. I believe rolling the discharge angled back slightly will
move the exhausted air away from you and dissipating better. In case you were standing still, it would prevent the discharged air from migrating back toward your helmet. I hope that helps, that's my official HVAC opinion !!

You could alway attach an outflow pipe to the exhaust fan to extend its discharge to the rim of the bucket, that way you could put the fan higher if needed.

You guys are awesome! Thank you for your constructive suggestions. I moved the exhaust fan down, towards the centre of the rear and rolled it away from my face.

I tried it on and quite honestly, this helmet is worlds more comfortable than my SE one now. I'll tidy up the cables and tape everything down so nothing gets snagged and disconnected by accident. With that, I am calling this helmet done...for now.

 

[tennantlim]

Just a couple of updates before I schedule my submission photos next week.

Weathered my neck seal by misting flat black.

Sewed the braids to my vest with fishing lines.

Painted, weathered and installed Dakota's flamethrower nozzles. They were spray painted flat black, buffed with steel wool and scratched with a pin at the ends.

 

[Fett 4 Real]

Do you plan to get a dented Right Breast plate?

 

[tennantlim]

Do you plan to get a dented Right Breast plate?

Hi Dom. I looked through the reference photos in the Gallery and found images that show variations on the right breast plate.

With dent:

Without dent:

Is there a version that is favored over another? Just want some clarity on this.

 

[Fett 4 Real]

The 1st without dent shot is the stunt suit notice his helmet? The rocket... the lack of hoses...

Some people go for it some dont... its something i think Id do for a strictly ROTJ suit. Its a nice touch.

 

[ShortFuse]

...and that bendy EE3.

 

[tennantlim]

The 1st without dent shot is the stunt suit notice his helmet? The rocket... the lack of hoses...

Some people go for it some dont... its something i think Id do for a strictly ROTJ suit. Its a nice touch.

Points taken and thank you Dom. Always good to learn a thing or two, but I'll use the one I have for now.

 

[tennantlim]

...and that bendy EE3.

Hey I paid good money for one!

 

[ShortFuse]

Yeah. No one can say they aren’t screen accurate.