Slave1Pirate's Aluminum ROTJ Boba Fett Build PIC HEAVY

Thanks! I appreciate your kind words!
Today I wanted to work on the knee rocket housings and finally get to using these greebles I made last year! I was only able to work on the left knee today.
Here is the 2d left knee rocket housing.
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I bent and welded the housing together. I decided to install a wall inside to mount the greebles to. I wanted the option to remove, replace or repair the greebles in case of any unfortunate accidents.
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The decided to bolt them in. Bolting them in means I need a way to access the screws with a tool. It also means that they could potentially come loose so I needed to make sure I had access. I drilled holes through the knee so that after I weld the rocket housing on, I can get the Allen key into there to tighten them up.
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Onto blending!
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That's all I could get done. A little more welding and blending to do and that portion should be complete.
 
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Today I worked on the 2nd pauldron. I got it hemed, welded and shaped. I took the 1st pauldron and made it the right side by putting the dents in it. The pair are in the last photo.
 

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I forgot to weigh the armor for you all. I'll try to do so tomorrow.

Today I began shaping the NEW helmet. I feel really good about this one so far. I really took my time slowly bringing it around.
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I clamped it together on a piece of 2x4 so I could weld the seam together. This will be ground down and blended and eventually cut out for the key slot plate at the rear.
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Here is after I welded it together.

I then began shaping the helmet to the aluminum template so the shape is correct where the dome meets the face wrap.
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Once I got it in place, I tack welded it to keep it there.
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I also fitted the lower aluminum template to ensure the lower portion retains its shape.
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All in all I'm happy with the results so far. It's definitely that wide squatty shape that the first one didn't have. My plan is to heat up the aluminum around the helmet to allow it to accept the shape that the 2 templates are forcing it to be in. Hopefully this plan works. The top and bottom templates will be removed after this and then it's onto the dome and cutting out the t visor and cheeks.
 
So today was a very rough day for me with this helmet. I began working on the dome. I rolled it and welded it into a circle and began the shaping process.
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I started welding it into place working my way around and taking my time.
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Once complete, I began bending the fingers in to form the dome. At this point I noticed something off. I went back to the drawings and realized what I had done. I welded the dome on backwards. I was so depressed and struggled to find a solution. At 1st I thought I would just beat it I to submission and weld the crap out of it. Eventually I arrived at "no, it will never be right", so I decided to cut and grind the dome out of it in hopes that I could still salvage the facial portion that I had worked so hard to achieve the shape of.
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After hours of toiling over the helmet, I had finally removed every last piece of the old dome with minor damages the the shape of the bucket. I quickly cut a new dome out of a different type of aluminum that I had laying around and began the work over again. This different type of aluminum argued with me as I attempted to weld it to the face portion.
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Alternating back and forth from one side to another, bending and welding the fingers to one another. The "correct" shape began to emerge as I moved along and I began to feel much better. The very center is not welded yet because they are very thin and tend to melt easily so most likely I will need to make a patch for the center on the inside. Once all fingers were tacked together, I removed the forms inside the helmet and made some adjustments. Here are the results from today's struggle. Tomorrow should yield so good stuff as I finish up.
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Slave1Pirate117 said:
So today I did a little welding and some grinding and some touch ups to a few pieces. I made a few adjustments and drilled holes for mounting the cod piece and kidney plate.
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When I got home I donned on the jumpsuit and mocked up the parts I had to double check fitment. Wifey helped me suit up. Please give me your honest opinions! Does anything catch your eye that needs fixing? I am aware that I need to bend the collar down a wee bit.
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The kidney plate requires adjustment as it is too loose.
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Excellent work! My only critique would be the back plate looks like it pokes out a little too much around the shoulder blade area. Here is a screen capture where it shows it’s a little more form fitting. Not sure how hard it would be to correct.

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ShortFuse said:
Excellent work! My only critique would be the back plate looks like it pokes out a little too much around the shoulder blade area. Here is a screen capture where it shows it’s a little more form fitting. Not sure how hard it would be to correct.

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I caught this the very night I took those photos and have been working on this since. Everyday I make an adjustment and fit it and adjust. I will repost with the corrections once it's perfect. Thanks for pointing out!
 
I have been quiet.....but busy. I had run out of the 14 gauge aluminum that I've been using so I used a lighter gauge I had lying around for the dome in the previous post. This was a struggle. Every weld created new holes, warped the dome and fought me every step of the way. My goal is to NOT use any filler but it seems I have gotten it to the point of pinhole filling and I'm fine with that. Here I begin shaping the ridge around where the dome meets the face wrap.
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Here begins the scary journey of forming the dent.
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This dent was not done like all my other armor pieces due to its shape and style. I cut put the hole and made the dent separately.
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I cut out my template and began making uneven bends with the press break. Here it is fitted into place.
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And welded,
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And here is the final cleaned up and sanded. What do ya'll think?
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Hey everyone! So besides a few tree limbs we had no damage from hurricane Ian although it got pretty nasty, we were lucky. We never lost power but it flickered constantly and that meant no internet. My only wish being trapped in the house during a hurricane was to be able to work on boba. We ended up playing highstakes Sabacc with the kids! We cleaned up the front yard and such and now the wife and I are here at the shop and we have some impressive updates on the helmet! Stay tuned!
 
Slave1Pirate117 said:
Hey everyone! So besides a few tree limbs we had no damage from hurricane Ian although it got pretty nasty, we were lucky. We never lost power but it flickered constantly and that meant no internet. My only wish being trapped in the house during a hurricane was to be able to work on boba. We ended up playing highstakes Sabacc with the kids! We cleaned up the front yard and such and now the wife and I are here at the shop and we have some impressive updates on the helmet! Stay tuned!
Click to expand...
Glad you're ok man. My in laws live in St. Pete. They came to stay with us and are headed back now. Keep up the good work. Looks awesome!
 
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