WIP Scratch build ROTJ from Ukraine

Mickey

New Hunter
Hi guys. Today I want to start my thread. At start I want to apologize for my english, this is not my native language. This topiс also a chance for me to improve my language skill.


I start build helmet at 17.07.2012. At the beginning I don't know anything about mandalorian, Boba Fett, organization and itc. I just want to build a helmet)


Unfortunately many photos “died” with my HDD, but I still have some to share with you.


I would be grateful if my experience will be helpful for someone.


Enough letters, let’s go images, and some video.


Helmet I build from cardboard by Alan Sinclair templates, many thanks for him.




All be fine untill I want to strengthen helmet by epoxy resin and fiberglass cloth.


Inside helmet I have ribs of stiffness, I broke them - wanted to walk through the resin inside. There was no danger.


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In the work the helmet fell - cracked the dome, burst in front.


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There is nothing that can not be repaired with glue)


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But I had one little problem. I cut out the visor too early and helmet lost shape (If you read this do not do like I do. Cut visor at end!) I made the inner shape of helmet from pvc and glue it inside by hot glue.


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And this works )


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Without experience I use more than necessary epoxy the dome.

- the helmet became heavier by about 200 grams

+ Now you can chop the nuts with a helmet )




After that I start to think how to attach visor to helmet (Now I know that exist this great forum where I can see how other people do, but then I don’t know this). And I start to improvise )

From bolts 4x10 with a hacksaw and file I turned out these things.

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I fixed them in 4 mm pvc, cut the grooves in the form of "rectangular" hats and insert the bolts there (they sit very tightly)

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Glue them, into a helmet.


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That how this looks inside

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That how this looks outside

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Using the same technology, we glue the whole form of the visor

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Time to try on the head

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Add some details:

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Everything seemed to be leveled, compared to how it was.

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Mickey

New Hunter
Interesting fact №1. Dent from laser shot made by boring milling cutter (I don’t know how it was in english) like this

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and finished with filler

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I little increased the size of the visor because it was not comfortable to me

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first trial installation of the visor


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At this time I decided to make my rangefinder stalk more stronger and thicken.

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Cut off the ear
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Interesting fact №2. The ears were cut from the hard styrofoam.


The glue I used, eroded the styrofoam from which the ears were made.

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Сut out the second half for the rangefinder stalk. Now I think why I did not use plastic?

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Made a groove for the wire in both halves of the stalk.

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Exemplary layout.

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With 3 try I made this small detail from pvc.

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Mickey

New Hunter
And this is all what I make in 2014)

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You will see more interesting things if you follow my topic.


I will try to post new posts as far as possible.
 

Mickey

New Hunter
Today I want to tell you what I done in 2015)

Year start from tinted visor and experimental install electronics.

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And how this works.


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Trial assembly of a cardboard gauntlet before making of plastic to find out what problem can be.

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Make some aluminium details.

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Starting of making knee armour.

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Making the shape of knee armour.

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