Mandalorian Mercs Costume Club

Mandalorian Armor => Helmets => Topic started by: michaeljscully on Jul 11, 2017, 10:42 AM

Title: Scully Helmet WIP
Post by: michaeljscully on Jul 11, 2017, 10:42 AM
Hey guys! I'm working on a Rubie's Jango two piece helmet, and wanted to share my progress so far.

This is my concept colors and layout—took off the range finder, and I'm adding a custom comm unit using some old WiFi antennas.
(http://i.imgur.com/59sWkcW.jpg)


Like I said, standard Jango 2 piece. This is what it looked like to start with:
(http://i.imgur.com/IorLoIn.jpg)


So far I've glued together the back and front, cut out the rounded cheek pieces in favor of flat ones, and added Bondo to smooth out the seam.
(http://i.imgur.com/QI8FyDP.jpg)
(http://i.imgur.com/ieOVtCL.jpg)

Do you guys reinforce the inside? I've been reading a lot and seems like there are a lot of schools of thought. I was probably going to plastidip the inside, but I see a lot of people use fiberglass. Which is preferable?
(http://i.imgur.com/4w2iTP7.jpg)


Thanks!
Title: Re: Scully Helmet WIP
Post by: Torolf Goran on Jul 11, 2017, 12:06 PM
You need to reinforce the inside with either fiberglass or glue in strips of plastic over the seam with plastic epoxy. If you don't the bondo on top will start to crack along that seam after a while.
Title: Re: Scully Helmet WIP
Post by: Ran on Jul 13, 2017, 05:59 AM
Plastidip isn't strong enough to reinforce it. I recommend fiberglass, not only on the top seam of the helmet, but also along the new cheeks you put in. It will make the whole helmet much stronger, and will keep the helmet from being so floppy, which will prevent bondo and paint from cracking, as well as just making it easier to work with.

Keep it up! Can't wait to see what Mulder's got cooking! :P
Title: Re: Scully Helmet WIP
Post by: Bowfanny on Jul 14, 2017, 10:52 AM
Plastidip isn't strong enough to reinforce it. I recommend fiberglass, not only on the top seam of the helmet, but also along the new cheeks you put in. It will make the whole helmet much stronger, and will keep the helmet from being so floppy, which will prevent bondo and paint from cracking, as well as just making it easier to work with.

Keep it up! Can't wait to see what Mulder's got cooking! :P
^^^This^^^^
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jul 15, 2017, 09:29 AM
Thanks guys! I used some plastic strips to reinforce the inside.

(http://i.imgur.com/DiI7MAg.jpg)

Do I need fiberglass in addition to that? I'm not sure what to get or where.
Title: Re: Scully Helmet WIP
Post by: Ran on Jul 15, 2017, 03:04 PM
Some just use plastc strips like that, but I still believe that the addition of fiberglass is vastly superior, and you'll be much happier with the end product.

Fiberglass can be found at any hardware store. The fiberglass resin comes in a can, and the can usually comes with a tube of hardener that you mix with the resin in order for it to cure. Also get fiberglass cloth which ahould be in the same section. Follow the instructions on the can to know ratio of resin to hardener you should use.

It's pretty simple to use, I used it for the first time on my helmet. I recommend gloves and a mask and/or applying it outside because it has a gnarly odor.

Rough of the inside of the helmet a bit with low grit sandpaper. Pre cut strips of fiberglass cloth to fit in the inside of the helmet, 3 or more layers for each section. Mix the resin and hardener and apply it to the helmet with a brush, then stick the cloth on and brush more resin on top. Repeat until you've used all the cloth you had cut. Then just let it dry.

It'll smell kinda funky in there for a bit, but just let it air out. ;)
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jul 20, 2017, 11:05 PM
Hey guys! Got some pictures of the new cheek plates now that the glue is dry. Still haven't fiberglassed it yet, but it's surprisingly solid despite that.

(http://i.imgur.com/0daQkVE.jpg)
Title: Re: Scully Helmet WIP
Post by: Ran on Jul 20, 2017, 11:12 PM
Looks wicked! Probably the best mod you can make to the J2p is replacing those lame cheeks, good job! ;)
Title: Re: Scully Helmet WIP
Post by: chevy42083 on Jul 21, 2017, 03:21 PM
Everyone has their own methods. This is how I interpreted the "plastic strip reinforcement"
http://mandalorianmercs.org/forum/index.php?topic=126206.msg1679509#msg1679509

Cover as much area as possible, with no room to wiggle (mine actually "snapped" in under the structure), and glued using a 2part epoxy that dries rock hard. I also put a bead of epoxy along that entire seem before joining the 1/2s.... so there would be NO gap at all. In my setup, Bondo should be purely a skin layer on top to smooth things out... no filling of voids/cracks. I still intend to add a 2nd, broader, layer of strips on the inside. I'm going to finish up some other areas of the helmet first.
(https://lh3.googleusercontent.com/ni0jxRd7mBXoUs2mYY_ytqnPYyHfY1rO9Y5cPoWyRqN-L9roOuXCd5El9u0mPmRRpPQ1giCxgqyHs39UvXyBkwaoo9dWsJ_az7Qic5qpOLlGS-0ygbdq9Jj738nUh4gAuDBU0JLI6hWlQqg-M6lKtN9hz9Aw4fLD8JphOo996ZSH26Eup6-FtxyVpyanlOkH2vC-xl-nwPWwYBd0h-d4p2Z284Tt3G0FNF8iwv3nhnZGC62vjs-Od_RLu41o8uB_YcF8XHaFPHQOv9aEztKfobJMIncTrDAX2YG-MjmwdbwOGS5InY_-pgxN2OaKdlOpSn6Jg1mX8gQHuGbeZDzG_ZqKJLXRGm_LWgbHzQbf7ir97nPI9U2KANEjFs0h-DdHRlMtt864fvcwRIoI0xKbWFUdhbTqz15A8QxmG5hqbq6VsurMbaQLjm_l7MjpP4LyOK3Cil620r9avkGkpqC5pb_o89qDNkb5PEBtEJlbRGUigdq44zs1tYefJbTTm17k29gFQ4aZcEXly1C6BdLXZVpJzKPp4xse2KKTOvyqYCpfRezDaU9YLZ_wQG-QwfXhtyvOqL2csItMYPBtpO9UOTWbzcu0JhhH5gQJGdf7lvX5lS7xOLhU=w1511-h945-no)
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jul 21, 2017, 03:27 PM
That's pretty much what i ended up doing. I used epoxy on the entire seam, and used plastic strips to reinforce it. There's not really any gaps in it, it's just a little bit rough, so used some Bondo to smooth it.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jul 24, 2017, 02:13 PM
After some Bondo and hell of a lot of sanding, I got the first layer of silver put on. It's a little transparent right now, because the can ran out after painting all of my armor and helmet at the same time.

It was so hot out it actually made the primer bubble a little bit in spots, but I thought it made for some interesting weathering, especially on the cheekbones.

Another trip to the spray paint store and I'll be able to post an updated pic.

(http://i.imgur.com/XB9Kuct.jpg)
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 15, 2017, 07:29 PM
Good work!! hows the space on the inside when you wear it?
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 15, 2017, 10:45 PM
Thank you! It fits great, actually! I heard this one runs small, but no problems. I can even fit my glasses on inside it. Here's an updated pic btw:

(http://i.imgur.com/dJxeTSL.jpg)

Added a custom earpiece on the right, going to add in a wifi antenna for a comm unit. Then paint, weathering and visor. Fans too, if I have time.
Title: Re: Scully Helmet WIP
Post by: Ran on Aug 16, 2017, 12:13 AM
Looks like you can still see the helmet seam. Before you get too far ahead of yourself with painting and whatnot, it'd be a good idea to sand the seam back down and apply more bondo. The seam should be completely invisible. Keep up the progress! ;)
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 16, 2017, 06:17 AM
Thanks!
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 16, 2017, 06:21 AM
Thank you! It fits great, actually! I heard this one runs small, but no problems. I can even fit my glasses on inside it. Here's an updated pic btw:

(http://i.imgur.com/dJxeTSL.jpg)

Added a custom earpiece on the right, going to add in a wifi antenna for a comm unit. Then paint, weathering and visor. Fans too, if I have time.

Oh that's right, you're trying to finish this before DCon yes?
I like how shiny it is right now :D adding your own created ear piece is very unique! I'll be waiting to see how you attach the antenna and the paint comes.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 16, 2017, 06:33 AM
Thanks! I have I think 17 days to get the rest of it done... It may not be 100% done, but it'll be as close as I can get it.

How does the seam look? It does show a little bit on one side, but I was thinking of camouflaging it as battle damage. Is that acceptable, or do I have to redo the Bondo?
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 16, 2017, 08:33 AM
Doesn't seem like you will need to just go over it again with some very fine grit sandpaper and see how that helps.
What was the original grain used?
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 16, 2017, 08:35 AM
I started with 120, then worked my way up to 800 or 1200.
Title: Re: Scully Helmet WIP
Post by: reguillet on Aug 16, 2017, 09:15 AM
I would add a little more, little being the operative word. You did a lot of ground work so just a bit will finish it. Smooth it with a craft stick and it will fill those tiny gaps well. I typically take down bondo with 80grit then clean up with 120. After about 3 sessions you will know how it will look. I polish with 320. Nothing finer.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 16, 2017, 09:37 AM
Agreed, personally use a razor blade to smooth things then cut off the bumps and whatnot. Like Reguillet said probably just a tiny bit will help some Vod.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 16, 2017, 09:40 AM
Thanks guys! I'm still getting the hang of Bondo. I needed to fill the spaces between the earpieces and helmet anyway, so that should be easy.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 16, 2017, 09:46 AM
Bondo seems like one of those things that takes years of working with before it starts to do what its told  :laugh:
How big is the earcap space?
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 16, 2017, 09:50 AM
Pretty miniscule on the front, but there's a bit of a gap on the back.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 16, 2017, 10:09 AM
Okay because mine do the same and I wanted to be sure it wasn't just my caps that were spaced some. Your color scheme is so vibrant!! Do you have the paint colors on hand or not yet?
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 16, 2017, 10:12 AM
Thanks! I have the paint already, I actually just finished the rest of my armor the other day:
(http://i.imgur.com/mXg8CxS.jpg)
(http://i.imgur.com/5awoOFn.jpg)
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 16, 2017, 10:45 AM
AHHHHHHH Yea!!!

That looks kandosii!!! Just blackwash left?
Title: Re: Scully Helmet WIP
Post by: Zando on Aug 16, 2017, 10:45 AM
AHHHHHHH Yea!!!

That looks kandosii!!! Just blackwash left?

What he said ^^^ Following with interest!
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 17, 2017, 12:34 PM
Yeah, just feathering the scrapes with some sandpaper, then black wash left for the rest of the armor.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 18, 2017, 09:06 AM
Got some time early this morning, so I applied some Bondo! No more gaps in the ear pieces, and the seam should be a lot smoother once I sand it.

(http://i.imgur.com/7rZCQTe.jpg)
(http://i.imgur.com/G10cM3b.jpg)
(http://i.imgur.com/cDlvGSj.jpg)
(http://i.imgur.com/WJYsVPZ.jpg)
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 18, 2017, 03:13 PM
Good, good, gooood
Looks awesome!!!
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 18, 2017, 05:51 PM
I also went back and filled in the gap between the top of the right earpiece and the helmet, so now it looks like it's embedded. I also decided I wanted more of a soft curve to where the cheek bone connects to the mandible, so I went in and filled that more too.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 18, 2017, 07:18 PM
Any special symbols or phrases going on the helmet Vod?
Cannot wait to see the results  :D
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 18, 2017, 07:21 PM
Putting some kill stripes of course, and I was thinking about writing "Revenge" in Mando'a somewhere on it.

Any suggestions? I'm open to better ideas.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 18, 2017, 08:32 PM
 :P I would hope kill stripes would be on it.

Perhaps a certain phrase or something someone important to you said would be interesting to have. Like
"Mandalorians dont make threats, we make promises"
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 19, 2017, 12:01 AM
I'm going to have to ponder what to write on it... I always liked Pvt. Joker's "Born to Kill" from "Full Metal Jacket."

But, now that the Bondo is almost dried, I have progress pics! The gap in the earpiece tasked me, so I filled it in, and took another pass on the cheekbones.

(http://i.imgur.com/q9IDgh8.jpg)
(http://i.imgur.com/rlgOyhy.jpg)
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 19, 2017, 11:04 AM
That looks much more unified now that youve added to it, not that it wasnt before  :laugh:

That is a good idea for a helmet, and FMJ is a great movie!!
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 22, 2017, 01:25 PM
Hi guys! Had to remove the Bondo and start over since I didn't add enough hardener and it was still gummy days later.

Also attached the antenna. After a bunch of false starts, I ended up filling it in with (what else?) more Bondo, then drilling a hole in the helmet and screwing the antenna in.

Finally, started re-priming the whole thing. There's still a few rough spots, but it's consistent with my armor, so fingers crossed it's ok.

(http://i.imgur.com/AUdHzyM.jpg)
(http://i.imgur.com/8P96nFa.jpg)
(http://i.imgur.com/cTpjChM.jpg)
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 22, 2017, 10:33 PM
Repainted the metallic silver all over, then added the "primer" level of paint. Next layer is going to be what's in my profile pic.

(http://i.imgur.com/wrjmbeJ.jpg)
(http://i.imgur.com/JGKEPbl.jpg)
(http://i.imgur.com/LvhpP1K.jpg)
(http://i.imgur.com/fBcb845.jpg)
EDIT: I accidentally a whole photo.
(http://i.imgur.com/5DU1aIF.jpg)
Title: Re: Scully Helmet WIP
Post by: Torolf Goran on Aug 22, 2017, 11:02 PM
It's looking good vod.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 22, 2017, 11:19 PM
Muchas gracias!
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 29, 2017, 12:15 PM
Quick update before I work on this today—adding in the white on the dome and the cheek plates, then the visor and black wash.

(http://i.imgur.com/7YqeP5T.jpg)
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 29, 2017, 01:53 PM
Looks good man!!
Like dat red and antennae   ;D
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 29, 2017, 03:50 PM
Thanks man! I'm going to have the whole suit done for Friday, so I'll definitely have more to post soon.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 30, 2017, 09:08 AM
Look forward to meeting you at D*Con then!!
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 30, 2017, 09:10 AM
Absolutely! I'm trying to find which events the Mercs are going to be at,  and I'm going to be at the Phasma book launch Friday night.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Aug 30, 2017, 10:11 AM
Few pictures to if thats alright haha
Last Alderaan Party I heard and then some other stuff as well, I wont arrive till Sat. Thats awesome youll make it to the book launch!!
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Aug 30, 2017, 10:27 AM
Btw, some updates: added the white, started removing the masking.

Going to attach the visor tonight, then do a black wash to finish.

(http://i.imgur.com/o4S0ysk.jpg)
(http://i.imgur.com/tkY30NV.jpg)
(http://i.imgur.com/lnplWQH.jpg)
(http://i.imgur.com/hv7MHYM.jpg)
(http://i.imgur.com/lLmhqwc.jpg)
Title: Re: Scully Helmet WIP
Post by: Zando on Aug 30, 2017, 10:34 AM
Looking awesome vod! I really love the weathering so far.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Sep 20, 2017, 09:31 AM
Somehow I managed to miss this update,

Everything is very well and consistently weathered it seems, the blackwash will really add that layer of detail!
Do you have little scuffs and marks throughout for it to seep into?
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Sep 20, 2017, 09:45 AM
Thanks man! The blackwash really brought out a lot of details. I had a lot of areas that are battle damaged, so there's plenty of spaces for it to get into. I was racing to get it ready for Dragon Con a few weeks ago, so it's not 100% ready on the inside, but I have a few pictures. I can get some more detail shots later on.

(https://i.imgur.com/eXmnqk3.jpg)
(https://i.imgur.com/4RsymtC.jpg)
(https://i.imgur.com/a63oSWa.jpg)
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Sep 20, 2017, 09:50 AM
BLACKWASH FOR THE WIN!!

Shame we didnt get to meet at D*Con but hey APs right?
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Sep 20, 2017, 09:53 AM
Yeah, I'll definitely be at the other events too, just have to fix everything that broke at Dragon Con first!
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jan 26, 2018, 02:37 PM
Been waaaaaaay too long since I updated this. Did a few things to my helmet since Dragon Con, so here goes:

(https://i.imgur.com/p1R4U03.jpg)

- Took off the antenna (it got broken off by somebody at Dragon Con, so I'm looking at replacements)
- Added the stoplight arrows
- Did a brown wash on top of the black wash to accent certain areas
- Reattached the right cheek (again, broken by a guy a Dragon Con)
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Jan 29, 2018, 12:33 PM
Looking very good so far IMO.

How did the damages happen? Bumping into someone or deliberately grabbing the antenna?
Title: Re: Scully Helmet WIP
Post by: Bowfanny on Jan 29, 2018, 09:28 PM
Looking very good so far IMO.

How did the damages happen? Bumping into someone or deliberately grabbing the antenna?
My guess is they dropped it.
Title: Re: Scully Helmet WIP
Post by: Ran on Jan 30, 2018, 12:42 AM
I think Droodles sells aluminum range finder shafts. I know Lonewolf sells resin sets.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jan 31, 2018, 09:29 AM
Thanks for the referral, I'm going to check out that rangefinder.

And it got broken because a hotel porter picked it up by the antenna. I was going for it so I could pick it up myself, but he was pretty fast. I could probably re-attach it, but I'm looking for something that sticks out from the helmet a little less--I think it was too wide anyway.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Jan 31, 2018, 12:42 PM
Thanks for the referral, I'm going to check out that rangefinder.

And it got broken because a hotel porter picked it up by the antenna. I was going for it so I could pick it up myself, but he was pretty fast. I could probably re-attach it, but I'm looking for something that sticks out from the helmet a little less--I think it was too wide anyway.

Always funny when someone picks something up by the smallest area. But like you said reason to make it better with aluminum.

@ Bowfanny Ive heard horror stories of the sound a bucket makes when it hits pavement..
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jan 31, 2018, 12:49 PM
Ah yes, I've heard of this sound. It's like all of creation stops and becomes silent for a moment, as if magnifying the horror of a cracked bucket.
Title: Re: Scully Helmet WIP
Post by: Nahtain Kaar on Jan 31, 2018, 03:01 PM
I dropped my helmet at my first con in gear. Star wars celebration. As soon as it hit the floor i saw three fully grown men almost cry. See, the thing is that it was sitting on top of my head as i was standing there talking to someone and forgot about it as i looked up. The sound it made when it hit made my heart drop and i was scared to turn around and look at it. All that's wrong with it is that there's a big chip out of the dome where it landed. I've never seen so many strangers show concern for my mental well being as in that very moment.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jan 31, 2018, 03:03 PM
Shared traumatic experiences bring us together. My condolences for your helmet.
Title: Re: Scully Helmet WIP
Post by: Yolah Hyperion on Jan 31, 2018, 03:08 PM
*A moment of silence for the dropped buy'ce around the world*  :'(
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jan 31, 2018, 03:10 PM
Pouring out some blue milk for my homies.
Title: Re: Scully Helmet WIP
Post by: Nahtain Kaar on Jan 31, 2018, 03:50 PM
Like i said, the helmet is fine. I'm gifting it to my girlfriend as the first peice of her armor since she wants to get into this as well with me. A smidge of bondo and it'll be good as new. Droodles' helmets can definitely take a beating. It took over a six foot drop and landed square on the dome and only chippedthe top layer. No cracks or anything si i'd say i got VERY lucky and that its a great bucket.
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Jan 31, 2018, 05:59 PM
Not bad! My first major upgrade (after finishing it) is going to be a new helmet. I love how cheap Rubies is, but the downside is that it's also very cheap.
Title: Re: Scully Helmet WIP
Post by: Kol Varek on Feb 02, 2018, 11:44 AM
Glad to hear you're making repairs vod. Nahtain, I strongly recommend modifying your posts. Tech Team doesn't like messages in all caps.
Title: Re: Scully Helmet WIP
Post by: Bowfanny on Feb 02, 2018, 02:15 PM
Oh all Caps only signifies yelling and doing it too much will make your caps lock button fall off.
Title: Re: Scully Helmet WIP
Post by: Nahtain Kaar on Feb 06, 2018, 01:37 PM
Yeah sorry about that. i work with autocad and have to keep caps lock on while at work and i just forget to turn the shabla thing off.
Title: Re: Scully Helmet WIP
Post by: Kol Varek on Feb 06, 2018, 08:55 PM
Sounds like a very angry and misunderstood work environment vod!  :P
Title: Re: Scully Helmet WIP
Post by: Nahtain Kaar on Feb 07, 2018, 03:29 PM
Didn't mean to side track the thread my apologies lol. Also michaeljscully if you are still interseted in the aluminum rangefinders from droodles i think he was prepping for a new batch of them either today or sometime soon have you talked to him about them yet?
Title: Re: Scully Helmet WIP
Post by: michaeljscully on Feb 07, 2018, 03:40 PM
No worries, it happens! I think right now I'm just going to work with component that I already have, until sometime after my tax returns get in.