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Author Topic: Alta's Bucket  (Read 28775 times)

Alta's Bucket
« on: Jun 28, 2012, 12:54 PM »
So with me worrying about time constraints and not knowing exactly what it is I'm doing, I decided to buy a bucket just in case. I got a Jango two piece from a wonderful seller on ebay and it just came in today! I plan to start working on it as soon as I finish my leg wraps but I have a bit of not sure where to start first syndrome. ^^; I know what I need to do with it as far as fashioning it after my design, but I'm not sure where to start as far as making it sturdy and trooping approved.

Should I start by sanding it down and gluing it together then going after it with bondo? And about the visor, is the reason it is not approvals as is because it is too light (i.e., you can see through it) or is it the visor itself (i.e., it needs to be replaced)? Just wondering if I need to make it darker or replace it all together (of which I can do either just need to know).

I've done some word searches but haven't completely found all the answers there. Any and all help would be appreciated.

Sedavor Til

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Re: Alta's Bucket
« Reply #1 on: Jun 28, 2012, 01:42 PM »
The order i did mine was:

1) remove visor- the visor won't work because it is to see through but you can use the visor as a template for the new one going in

2) sand down the visor notches, I found it easier to do this before glueing the 2 pieces together, 

3) Modify Cheeks - this is optional,  I personally do not like the way the curved cheeks so I replaced them with Sintra to make them straight.  Again it was easier for me to do this with the 2 pieces seperated and again is optional

4) Glue the pieces together

5) Secure the inside seam - I used Bondo Glass along the inside of the seam but Ive seen others just glue down extra peices of for sale signs or sintra.  This helps keep the helmet together and helps prevent extra stress on the bondo on the outside seam

6) Bondo the the seems on the exterior of the helmet - now with this you can do just along the seam or the entire dome

7) sand and sand some more

8 ) once smooth apply paint apps

9) apply new visor - I used a green welding face shield

Again this is just the order I found easier to work with.   
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Re: Alta's Bucket
« Reply #2 on: Jun 28, 2012, 02:15 PM »
Thank you so much! I appreciate the help as I have no idea what I'm doing here. ^^; A few questions though:

1) Is there no way to darken the visor? Don't they sell some of those tinting strips in auto shops? I don't mind replacing it if need be as said before, I'm just curious as no one in my town will sell me a face shield without making me buy the helmet too which makes it cost a lot more. Again though I will gladly buy the helmet and all if that is what is required.

2) How would you suggest removing the visor? I'm pretty sure I could get it out but I'm also pretty sure there are probably safer ways of removing it then just ripping it out. Any suggestions?

3) I like the idea of modifying the cheeks (I didn't know they were so curved until you pointed it out, thank you for helping me to see that :)  ) How would you suggest going about removing them safely? Dremel? And how did you attach your new check pieces? Just glue them in?

4) Also, and this may be a ridiculous question but, what do I do with the ear caps when I finally get around to bondoing the whole thing?

Sorry for so many questions. ^^; Just wanting to make sure I get this right (preferably the first time lol).

Hondo Karr

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Re: Alta's Bucket
« Reply #3 on: Jun 28, 2012, 02:36 PM »
1. Yes you can but, a dark green welding shield is as cost effective as buying tint and as the tint doesn't like to stay permanantly attached to a curved surface, the dark green (which appears black when installed) won't fail down the road.

2. You can just pry it out or snip the tabs holding it in place, helpful hint is to hang onto the visor and use it as the template for your new one.

3. Yup, a dremel would work fine.

4. The earcaps can just be glued back on after the sanding work is done. While it's not required, I would recommend rebuilding the right earcap as the one it comes with is terrible!

Jerek Darr

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Re: Alta's Bucket
« Reply #4 on: Jun 28, 2012, 02:40 PM »
Use a sanding drum to burr off the nubs holding the visor in, then use the same bit to sand down the posts, you could attempt to tint the visor, but the possibility of bubbles occuring over time are pretty high. Replacement sheilds are redily available, http://www.amazon.com/SAS-Safety-5152-Replacement-Faceshield/dp/B002YKO0Z0/ref=sr_1_fkmr2_2?ie=UTF8&qid=1340908093&sr=8-2-fkmr2&keywords=dark+green+face+shield+visor

As far as removing the cheeks, a dremel is the safest way, use a high strength adhesive like E-6000 to glue in the new cheeks, the seam can be smoothed out with bondo.

I reccomend gluing the earcaps on and filling the seams before painting.

Remember bondo is a body filler, NOT an adhesive, I also reccomend giving the whole bucket a light sanding BEFORE bondo, to make sure any mold release agent is removed.

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Re: Alta's Bucket
« Reply #5 on: Jun 28, 2012, 02:53 PM »
Thank you all for all of the advice! I hope to get to work and have pictures up of progress very soon! Any other tips or tricks yall can think of are greatly appreciated. :)

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Re: Alta's Bucket
« Reply #6 on: Jun 28, 2012, 05:08 PM »
... I hope to get to work and have pictures up of progress very soon!...

Can't wait! ;D
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Re: Alta's Bucket
« Reply #7 on: Jul 03, 2012, 12:29 AM »
Sorry about the delay. Injured my back Friday and it put me behind schedule. All better now though and am back to work. Here's what I got so far on the helmet.




Hopefully will have more to show soon. :)

Kalaval Zil

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Re: Alta's Bucket
« Reply #8 on: Jul 03, 2012, 12:55 AM »
really gooooood start!
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Re: Alta's Bucket
« Reply #9 on: Jul 03, 2012, 02:36 AM »
really gooooood start!

Thank you :) I hope the rest of it keeps going well ^^;

On another note, I had a few quick questions for yall regarding reinforcing the inside of the helmet.

1).  In the picture below, a portion of the inner helmet near the right ear cap is circled in red. That particular part is incredibly flimsy and is making me nervous. I want to reinforce it but I'm unsure which way will give it the most strength. I have some fiber glass mat I bought from an auto store, that I hope is the right kind (the guy referred to it as kitty hair fiberglass mat) and was wondering if I should use that and then reinforce it with a plastic panel or panel and then mat/fiber glass it.  Thoughts?



2). Regarding reinforcing the dome with a plastic strip, should I do one long strip and go with the seam or several short ones and slip them in between the little post pieces? This may be a ridiculous question but well...I don't want to take any chances. ^^; The picture below better shows what I'm talking about.



Any thoughts? Any and all help would be greatly appreciated!
« Last Edit: Jul 03, 2012, 02:17 PM by Alta »

Re: Alta's Bucket
« Reply #10 on: Jul 06, 2012, 01:39 AM »
Picture spamming time! I've been hard at work for the last few days and have several pictures of my helmets current state in the transition from Jango two piece to custom mod. Here's what I got so far.

I dremeled off all of the nob things on the side of the bucket. Reason being I was doing it for the right ear cap as I was going to just make a simple one out of plastic but then realized it would look odd with the original one on the left side so I did the same to it as well. Here are the two sides now. (The raised portion in the first picture is excess glue. It will get cleaned off before any bondoing is done, no worries.:)  )



Here is the new ear cap I cut out today. Only the left one is semi ready as of right now. I may or may not dress it up with some newspaper board that I have stashed away simply because the head wrap in my design will likely hide any work I actually do on it. Still haven't decided as of yet. Any way here are a few shots of it. (Mind you it's not attached I just propped it up next to it to give yall a better idea of what it will look like.)




And last but not least, here are some inside shots to show the work I've tried to do regarding strengthening the seam area.




So, what do yall think? Am I doing OK? And what do I do next as far as the inside portion of the seam goes? Bondo then bondo mat then more bondo then sand till my hands fall off then repeat for the outside? Any and all advise is appreciated. :)

Kalaval Zil

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Re: Alta's Bucket
« Reply #11 on: Jul 06, 2012, 01:44 AM »
WOW you are really handly! you are doing it real good!!!
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Re: Alta's Bucket
« Reply #12 on: Jul 06, 2012, 02:03 AM »
WOW you are really handly! you are doing it real good!!!

Thank you  :D I'm trying really hard to do this right the first go round. All of the helpful tutorials and awesome advice I've been given from everyone here has really, really helped a lot! Hard to imagine that I hadn't ever used a dremel till this week. ^^; But thanks to all the tips I've read around here things went pretty well I think. :)
« Last Edit: Jul 06, 2012, 02:24 AM by Alta »

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Re: Alta's Bucket
« Reply #13 on: Jul 06, 2012, 04:27 AM »
A tip if this is your first time using bondo- really rough up the surface your are applying it to so it has something to bite and apply it in THIN coats rather than thick globs. It's much more manageable and effective to do 2-3 rounds of filling and sanding than to try and get it all in one shot. Your results will also be much better.

Jerek Darr

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Re: Alta's Bucket
« Reply #14 on: Jul 06, 2012, 07:04 AM »
Have you test fitted the bucket now that you have modded the cheeks? The reason I ask is it is possible to catch your cheeks on the extended upper curved edge of the new plates (I had this issue with my HBF mod). It is just easier to tirm those down now before you start "body work".

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