Mandalorian Mercs Costume Club

Mandalorian Armor => Helmets => Topic started by: Jorbe Falco on Dec 13, 2015, 01:53 PM

Title: Jorbe Falco's Target bucket WIP - Almost done!
Post by: Jorbe Falco on Dec 13, 2015, 01:53 PM
Hey! I had to burn some vacation days at the end of the year and finally got motivated enough to actually make some progress on my bucket.

A few weeks ago I took it to my brother's house and we used his heat gun to try and pop out the dent.

Before (http://i.imgur.com/5V1uHQkl.jpg) After (http://i.imgur.com/cEtWpxYl.jpg)


We were successful, although it kind of warped the dome a little and left the area around the dent a bit lumpy.

(http://i.imgur.com/Qlk842el.jpg)

This was my first time working with Bondo. There was a slight learning curve, but I'm getting the hang of it.

It wasn't apparent to me how off it was until I sanded the second coat of Bondo. It wasn't totally off... but I didn't like it.

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

After a MASSIVE third coat of Bondo and A LOT of sanding..... I'm finally satisfied with the shape of the dome.

(http://i.imgur.com/C1DlxOMl.jpg)

So that's where I am right now. I need to e6000 the inside of the dome and the seams. Then bondo the outside seams and the rim of the dome. I also want to fiberglass the inside to make the thing solid.

Not quite sure what I'm doing on the earcap. I may want to mount a light on the side.

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

Also, for you Bondo experts out there. What am I doing wrong? Every layer I put on I seem to have these pits in there. Are those air pockets? Ideas? Thoughts? Advice? Criticisms? Any feedback would be appreciated.

(http://i.imgur.com/Qsyz83ol.jpg)
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Bowfanny on Dec 13, 2015, 02:45 PM
Looking good. Those little pains are why they invented spot putty. Or if you're feeling adventurous you could mix up a small batch of rondo and paint it on and sand that back down and most of those pin holes will go away. I personally like rondo for that reason.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Kavryn Falco on Dec 15, 2015, 02:44 PM
That whole process is pretty much exactly what happened with my brother's bucket, haha.  Wish I'd just filled the dent in the first place instead of trying to push it out... oh well, live and learn.

Yup, bondo spot putty is the champ.  Bondo for large areas, putty for finishing.  The spot putty is really only good for pinholes and small divots because it doesn't set hard, so use it sparingly.

Give it a primer coat and see if there's any areas that need additional sanding.  Oftentimes the different colors can mask imperfections, and spraying it with a coat of paint will help you see if there's any additional areas that still need work :)
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on Dec 15, 2015, 04:13 PM
Funny you should say that. I hit it with some primer, then sanded a bit, and hit it with primer again. It looks a lot better now, but I can still see some rough patches.

(http://i.imgur.com/hJHFYOa.jpg) (http://i.imgur.com/b8aF5dc.jpg)

I'm using 120 grit sandpaper at this point. Should I be using something higher than that?
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Kavryn Falco on Dec 15, 2015, 04:22 PM
I use 80 for big sections and heavy removal, 120 for midsize blemishes and feathering, and 300 for finishing (basically, removing the scratches left by the other two grits, haha). If it's not as smooth as you want it, I'd say keep going with the 120.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on Dec 15, 2015, 04:37 PM
Awesome. Thank you. I'll pick up some 300 and give that a shot.

UPDATE

Didn't have much time tonight, and didn't get to pick up the 300 grit or spot filler... but was bored. So I primed the rest of the helmet.

(http://i.imgur.com/X2GStCxl.jpg)

ANOTHER UPDATE

Ordered a coverall/flight suit

(http://i.imgur.com/yph6Dnt.png)

Also, I have revised and finally (I hope) come up with a color scheme that I like.

(http://i.imgur.com/U2NALgL.png) (http://i.imgur.com/Y460GxC.png)

I'm going to replace the RF with a light and/or camera. Haven't worked out the exact placement or mounting. But I'm also going to build some tools and apply to be a Mechanic in the Support Division.

Lastly, I picked up some 2 part Bondo Spot Putty / Glaze and some 320 grit sandpaper. So I hope to finish that part of my bucket soon.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on Feb 08, 2016, 02:21 PM
Haven't update this thread in a while, but I have been working.

I fiberglassed the inside of my bucket! Totally not as scary as it was in my head.
(http://i.imgur.com/bdMJwgW.jpg)  (http://i.imgur.com/laoVtM5.jpg)

Just about finished with the sanding and priming.
(http://i.imgur.com/pYNhHi8.jpg)  (http://i.imgur.com/yNiPTbK.jpg)

The one spot over the earcap is still a bit wonky, but it's going to be covered with a light, so I'm not worried.
(http://i.imgur.com/E9jFn49.jpg)  (http://i.imgur.com/GlrYn7K.jpg)

Trying to get the light positioned correctly was a pain... so I found an old piece of paracord and used that to find the center of the bucket.
(http://i.imgur.com/rnX12CG.jpg)  (http://i.imgur.com/5apN6Uf.jpg)

Waiting for glue to dry.
Put down painters tape, glued the light in the correct position. Will remove the light and then go to work with Bondo and/or Apoxie Sculpt to fill in the voids and build up a platform.
(http://i.imgur.com/2cXJFGi.jpg)

Once I had a center line, I was able to position the light so it pointed forward.
(http://i.imgur.com/EK6EbBX.jpg)

I also fabricated this to go over the light so it looked less like a modern tactical flashlight. Will most likely greeble it up as well.
(http://i.imgur.com/SZifmKB.jpg)

The mirror tint for my visor should arrive tomorrow. I also have the spray paint I need for my kit. Hoping to have the bucket at least display ready by the end of the week.

Thoughts? Suggestions? Questions?
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Raestin Ke'Varek on Feb 08, 2016, 02:52 PM
That's some really great work so far vod!  The bondo work came out great, and I love the idea for the flashlight cover.  Very cool.  :D
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on Feb 12, 2016, 03:49 PM
Light is on! Just need to clean up the mounting area and prime it.

(http://i.imgur.com/zVXTuc4.jpg)
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Kavryn Falco on Feb 12, 2016, 04:01 PM
Oooh nice! You gonna blind some people :laugh:
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on Feb 12, 2016, 04:12 PM
Yes ma'am. I aim to misbehave.  ;D  It does strobe too... ???
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Kruser on Feb 12, 2016, 08:38 PM
Keep up the good work!
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on Feb 27, 2016, 05:01 PM
Haven't updated this in a while... so here goes!

I made this! I have since cleaned it up and primed it. I also attached it to my bucket TODAY. Pics of that will follow. Trying to stay in order.
(http://i.imgur.com/qcj8Hra.jpg?1) (http://i.imgur.com/Wb9ME6Q.jpg)

Cut my keyholes slots out! Also, cleaned up the area that the mount/light will go.
(http://i.imgur.com/lR88PyI.jpg) (http://i.imgur.com/8wVveEW.jpg)

Mirror tinted a visor today.... also tested a blue gel on it. Not sure which way I will go. Will depend on what goes better with paint.
(http://i.imgur.com/FgQu992.jpg) (http://i.imgur.com/PgRTGJk.jpg)

Here is me gluing the rail on.
(http://i.imgur.com/xXbGTpN.jpg)

Done and done. Need to actually bolt it on and throw some Bondo around it where it meets the bucket.
(http://i.imgur.com/QCownIj.jpg) (http://i.imgur.com/2DCLccX.jpg)

Finally, I glopped on a second layer of fiberglass resin. There were some rough parts inside that I had sanded down, but I wanted the inside to be smooth and I figured it would add a little more strength.
(http://i.imgur.com/8h3swT6.jpg)

I cut out some armor plates as well, but I'll save that for my armor thread.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Kol Varek on Feb 28, 2016, 11:11 AM
Glad I caught this! Before you go ANY further, I would get in touch with an app team member about that side mount. They might see it as too "earthy" and it could get you dinged in your OM application. So before you paint or anything, PM one of them and see if they'd want you to take it off. Keep in mind that you can always rig something else up to attach something to the side of the helmet, so no loss if it has to go. Good work so far though!
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on Feb 28, 2016, 03:50 PM
Thanks for the concern, but I'm not worried. Once the light is attached, you can't even see the mount. It's the light itself that I need to swarz up a bit.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on May 02, 2016, 11:26 PM
Some updates!

(http://i.imgur.com/fC2ftAZ.jpg)

(http://i.imgur.com/wRnm4Br.jpg)

(http://i.imgur.com/uCPn3xe.jpg)

(http://i.imgur.com/7BIkMON.jpg)

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

(http://i.imgur.com/VDV1MuI.jpg)

(http://i.imgur.com/cFoFQrj.jpg)
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Coder on May 03, 2016, 09:04 AM
so i gotta ask... i have one of these on the way and i need a size comparison to someones body. just how big a boy are ya?
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Raestin Ke'Varek on May 03, 2016, 09:11 AM
Looking really good vod!  Off to a great start!  :D
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on May 03, 2016, 09:52 AM
so i gotta ask... i have one of these on the way and i need a size comparison to someones body. just how big a boy are ya?

I'm 5'11" about 215lbs. I enjoy long walks on the beach and basket weaving.

All jokes aside. That's my height and weight. I also have a big meat head, and this bucket fits great. If you look at my armor WIP thread (link in my signature) there are some full body pics of me with the bucket on. I was about 20lbs heavier in those pics.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Draceline on May 03, 2016, 09:57 PM
Looking good there! You and your lightweight bucket. Soon enough it will be time to work on the verd'ika's helmet instead of your own!
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on May 04, 2016, 08:00 AM
Looking good there! You and your lightweight bucket. Soon enough it will be time to work on the verd'ika's helmet instead of your own!

It is pretty light. It's not something I had even considered until I held a bunch of resin cast buckets at Chase Con. Those things were heavy compared to this.

As for the verd'ika... soon enough. I actually wanted to start glassing his bucket but it's been raining for a week and I'm not going to fiberglass inside again.... got yelled at by the wifey the only time I ever tried that... and she wasn't even home while I was doing it.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Draceline on May 04, 2016, 06:23 PM
He learns! Hah! I wouldn't have tried glassing in the house in the first place. Trust me, I'm hating the rain too. I need to bondo. I can sand in the basement, but I'm not sure I ought to use the bondo down there even with the respirator. It's too dark, honestly.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on May 04, 2016, 06:32 PM
He learns! Hah! I wouldn't have tried glassing in the house in the first place. Trust me, I'm hating the rain too. I need to bondo. I can sand in the basement, but I'm not sure I ought to use the bondo down there even with the respirator. It's too dark, honestly.

I've bondo'd in the house as well... got yelled at for that too. Even with the downstairs door and window open and plastic taped over the door. The smell will go away, but it takes a while.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Bowfanny on May 04, 2016, 06:42 PM
I Bondo under an RV awning and let it sit under there until it cures
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Thomas.berubeg on May 04, 2016, 06:43 PM
Yeah, I'm no longer allowed to use "chemicals" in the Apt, e
Even with the fan blowing behind me and put the door. :-(
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Darth_Vemon on May 04, 2016, 09:20 PM
I have a similar build going on, also with the intent to apply as a Brigade Mechanic. 

My light, also mounted with a rail, is on the left side of my lid, and I also reworked my RF to fit a light as well. 

Following this closely as its along the same vein as my own build.  Looks good so far.
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on May 08, 2016, 07:36 AM
So had some free time yesterday (which is rare) and decided to start painting the bucket. The plan is to layer the paint, masking damage as I go. I started with the base "metal" layer. Added masking fluid for damage/wear. I applied the fluid with either a thin brush or a piece of coarse styrofoam. Having never done this before, I have no idea what the end result is going to look like. Oh well. We will see.

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

After I was satisfied with what I masked, I hit the entire bucket with a few layers of white. This is to simulate a primer layer and give the weathering some depth. I chose white because my main paint color is a darker blue and I wanted to have some contrast here.

(http://i.imgur.com/AzHkb7q.jpg)

After a few coats of white, I let the paint dry for a while. I then applied a bit more masking fluid in the same spots, traveling outside the original areas in some places. This will hopefully reveal some of the "primer" while not going down to the base "metal" layer.

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

Next up... blue!

(http://i.imgur.com/TiwC2HX.jpg)

Hit the bucket with a decent layer of blue, my primary color. Didn't focus too much on the mandables, as these will be orange. I may give them a cover of blue on my on the second coat... not sure yet. That's all I was able to do yesterday as I ran out of daylight. I hope to do another coat of blue today, but it's Mother's day and raining... so my time is limited.

(http://i.imgur.com/BjmqXFp.jpg)
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Coder on May 08, 2016, 04:23 PM
That will look good with orange.....not that I'm biased or any thing :P
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on May 09, 2016, 05:03 PM
Blue is dry... Ready for orange!

(http://i.imgur.com/CTn5pmP.jpg)

Blue areas masked off and orange is applied! I did one heavy-ish coat of orange and then a second as soon as the first was tacky. Then I removed the masking tape before the orange was dry.

(http://i.imgur.com/FeF7Ohd.jpg)

As you can see, the masking tape pulled a little of the masking fluid off in spots, and some regular paint in others... but overall I think it just adds to the wear and tear look.

(http://i.imgur.com/QBL9mEx.jpg)

(http://i.imgur.com/0lgiZ2N.jpg)

(http://i.imgur.com/D6oIs8P.jpg)

(http://i.imgur.com/WOApb3s.jpg)

I had some time this morning, so I started to pull some of the masking fluid off. I'm not done yet, but it's starting to come together and I'm incredibly happy and relieved. Next steps are going to be finishing with the masking fluid, cleaning up some overspray spots, and blackwashing everything to make it look grimy. Then I just need to install the visor and put some foam inside.

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

What does everything think? Am I on the right track?
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Raestin Ke'Varek on May 09, 2016, 05:26 PM
Looks solid so far vod, I'm definitely a fan!  Before you blackwash it, I would add some various scratches to it with some different grit sandpaper, knife, screwdriver, wire brush....etc.  That will give the blackwash something to sink into for a bit more realistic look.  :)
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Darth_Vemon on May 09, 2016, 11:47 PM
What are going to do to disguise the picatinny rail? 

I'be done the same thing, using a rail to mount a light (see helmet WIP), and was told it wasn't the best idea, too obvious as to its origin. 

I've since layered it up with putty.  Once it has fully cured I'll see how it looks. 
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: The Unknown Mando on May 10, 2016, 02:33 AM
Not bad vod, nice colour combo too
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Jorbe Falco on May 15, 2016, 12:26 PM
What are going to do to disguise the picatinny rail? 

I used putty to contour it to the helmet. It's a pretty small section of rail compared to the light, so you can't even tell it's a rail once the light is attached. I'll probably add some greeblies or cloth tape or something once the light is attached to further obfuscate the method of attachment.

-UPDATE-

Blackwash applied!

(http://i.imgur.com/c5yB1na.jpg) (http://i.imgur.com/JDSCsbd.jpg)

(http://i.imgur.com/CEgvNCf.jpg) (http://i.imgur.com/rfTlx98.jpg)
Title: Re: Jorbe Falco's Target bucket WIP - Lots of pics
Post by: Coder on May 15, 2016, 12:38 PM
Really like I got this so far
Title: Jorbe Falco's Target bucket WIP - Almost done!
Post by: Jorbe Falco on May 18, 2016, 09:15 AM
Made some progress last night.

Finished weathering the light. Also hit it with blackwash after and then assembled it.

(http://i.imgur.com/87ggydL.jpg)

Mounted the light.

(http://i.imgur.com/ERb6scN.jpg)

(http://i.imgur.com/Ilf9Nn6.jpg)

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

Made a quick visor template. Shined a light from underneath. Worked well.

(http://i.imgur.com/0IzGhKT.jpg)

Cut out my visor and just kind of stuffed it in there to see how it looked. I like.

(http://i.imgur.com/RpxtR0s.jpg)

Originally I had considered using these blue gels... I think I like the plain mirror more.

(http://i.imgur.com/lMJXtp1.jpg)

UPDATE:

Made a dirty cloth/rag wrap that is "holding" the light on.

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

(http://i.imgur.com/5FR6amH.jpg)

(http://i.imgur.com/knvu7oj.jpg)

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

NEXT STEPS:

Title: Re: Jorbe Falco's Target bucket WIP - Almost done!
Post by: DavidC on May 23, 2016, 07:48 PM
Looking good homes!!
Title: Re: Jorbe Falco's Target bucket WIP - Almost done!
Post by: Jorbe Falco on Sep 25, 2018, 04:56 PM
Annnnd, I'm back!

It's been a while, but after attending NY Maker Faire this past weekend, I've come out of build limbo. I re-tinted my visor and finally installed it in my bucket. I installed some foam inside but this will just be temporary as I play on ordering some professional helmet padding.

Some shots right after I installed the visor!
(https://i.imgur.com/l3wKnwH.jpg)
(https://i.imgur.com/0VxbzWJ.jpg)

<Image removed by moderator for inappropriate gesture>


Wearing the bucket at Maker Faire!
(https://i.imgur.com/wxWmkzz.jpg)

Up-bucket beard shot.
(https://i.imgur.com/bE1YCYf.jpg)

On display!
(https://i.imgur.com/trgyNUK.jpg?1)

Let a little guy try on the bucket. Hopefully I've inspired him to grow up and be a Mandalorian!
(https://i.imgur.com/frYxBsq.jpg)

Plan on adding better padding, a fan, and I'd love to add one of those gaskets at the bottom. Need to figure out who makes those.

-JF