Mandalorian Mercs Costume Club

Mandalorian Armor => Helmets => Topic started by: Ko'rizna Falco on Jun 18, 2018, 12:04 PM

Title: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 18, 2018, 12:04 PM
Alright I'm jumping into the deep end head first on this one. I am new to not only the Mercs but cosplay in general, though I've always wanted to get my hands dirty. I'm going big by starting with a home made "homer" bucket. I'm taking things slowly and I will be posting a ton of pictures as I go, hopefully I can turn this into a successful tutorial after I'm done.

This is all of the equipment I either bought or had to build this helmet (the manila folder is my templates)
(https://i.imgur.com/BGsXFGz.jpg)

This is the Hard hat after cutting off the brim all the way around.
Front:
(https://i.imgur.com/S58lRPC.jpg)

Left:
(https://i.imgur.com/Nt9BIbl.jpg)

Right:
(https://i.imgur.com/E1Chlb0.jpg)

Back:
(https://i.imgur.com/uZpwdXS.jpg)



I really don't  like the front of  the helmet, I am first going to try and see if it will work backwards, and if not I plan on creating a continuous center ridge from front to back with some sintra and bondo. I also have my templates cut, modified (for night owl visor), and taped. I just have to transfer them I know it's not a lot here but I wanted to get started and get some very early feedback.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 19, 2018, 08:28 PM
Now I have more work done on the actual buckets for the helmet:
The blank layer:

(https://i.imgur.com/0rySQOl.jpg)

and the visor layer:

(https://i.imgur.com/Ynhq6NY.jpg)

(https://i.imgur.com/6PHa7CZ.jpg)

(https://i.imgur.com/rShf26Q.jpg)

(https://i.imgur.com/jYYKZ9Q.jpg)

(https://i.imgur.com/0V437Z1.jpg)

(https://i.imgur.com/wnK3ZLf.jpg)

I would love some critique, constructive criticism, or compliments and encouragement if you have it. Thank you.
Title: Re: Homer bucket First Attempt WIP
Post by: zaineordo on Jun 19, 2018, 10:16 PM
hey Vod, dont know if its just my phone, and comp but your images aren't showing up. and if it is please ignore. 
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 19, 2018, 10:18 PM
Oh man. Thanks for the heads up. I'll see what I can figure out.
Title: Re: Homer bucket First Attempt WIP
Post by: zaineordo on Jun 19, 2018, 10:20 PM
Imgur is fantastic and really simple to use. 
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 19, 2018, 10:22 PM
Thanks I'll use that and get it figured out tomorrow. Thanks for letting me know. I gave it a day and saw responses around my post and was very confused. I'm glad it's user error. And not me getting ignored or something.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 20, 2018, 10:38 AM
Imgur is fantastic and really simple to use. 

All fixed I hope. Uploaded to imgur made the images public and should be good to go. I hope
Title: Re: Homer bucket First Attempt WIP
Post by: zaineordo on Jun 21, 2018, 06:56 PM
yup all good to go shows up and looks fantastic
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jun 21, 2018, 07:21 PM
Pics are up.  Welcome to scratch building :)

You probably want to sand or cut off the little nubs on the sides so that your brow ridge can be flush with the main part of the dome.  Be sure to rough sand all your plastic NOW so that you don't have to do it after assembly as it's a bit trickier. 

Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 21, 2018, 07:44 PM
You probably want to sand or cut off the little nubs on the sides so that your brow ridge can be flush with the main part of the dome.

So those nubs are actually where the inside rim, brace, padding thing attaches to the helmet, I was planning on using that since it came with the helmet to keep it comfortable on my head but I could just as easily go buy some bike helmet padding if you think that would be a better option. Since you're on the app team then i'd love to hear what you think and will defer to that since that is the ultimate goal of course
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jun 21, 2018, 08:00 PM
My real resume for this thread isn't the app team tag, it's this thread:   https://mandalorianmercs.org/forum/index.php?topic=130486.0 (https://mandalorianmercs.org/forum/index.php?topic=130486.0)
This thread too: https://mandalorianmercs.org/forum/index.php?topic=152021.0 (https://mandalorianmercs.org/forum/index.php?topic=152021.0)
This was the resulting helmet:
(https://i.imgur.com/Eptzntf.jpg?1)

You're going to end up having to cover those nubs if you don't cut them off.  I wound up putting just some EVA foam inside my helmet for padding, but people also use the bike kits, the baseball kits, and the military helmet kits.    The danger of leaving them on is that you're either going to have difficulty attaching the brow ridge, have an abnormally thick brow ridge, or need to give those nubbins some kind of purpose so they look like an intentional part o your build instead of left over hardhat.

The choice is very much your's, and I look forward to seeing what you decide :) 

Happy to answer any questions you have vod!

Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 21, 2018, 08:45 PM
Wow! Those both give me amazing insight and a lot to think about. My Initial thought was to actually screw into the nubs so that the top of the brow was level with the top of those nubs and just have an extended brow ridge, but now that I am looking at it I have some serious thinking to do. That may end up being too thick.

My thought is to cut out the buckets (or at least the base layer) and mock fit those with duct tape or something to get an idea of what I'm dealing with, and what size the bucket ends up being. Then I need to see how big of a ridge that leaves and if I think it is manageable or needs to be brought in by removing those.

Thank you so much for the insight as I had been working from just one WIP from a clan member and Youtube video. Those are great references.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jun 21, 2018, 08:53 PM
A lot of the WIPs and threads I learned from got killed by the Photobucket User agreement change, so that's why I wound up doing the tutorial. The WIP I just did so I could keep getting feedback. Getting feedback is pretty key, and you're doing that.  Trying things and seeing how they look is also key. 

Also, don't get pissed at yourself if you end up making 1, or most of 1 to learn, and the final bucket for your kit ends up being the second. At some point in the build, you WILL want to throw it against a wall... at that point, just keep sanding :p so much sanding...

Sep
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 21, 2018, 08:55 PM
HAHA Thanks, I'm trying to go slowly and get all the feedback so this is a one shot deal. Though in the back of my mind I know it isn't lol. I'm totally new to cosplay and the Mercs so to get it on the first go would be a miracle.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jun 21, 2018, 08:58 PM
I am slowly coming to accept that I'll be happier with the final result if I just go ahead and plan on throwing the first one away (if it's a new technique/skill for me), so I don't try to keep bandaiding the first one and then get something I accept only until I get fed up with it and remake it later.  Which is why I'm OM a little over a year, and on my second set of just about everything....  But I was brand new to cosplaying when I jumped in too.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jun 23, 2018, 11:13 PM
Haha I appreciate the advise you have truly been very helpful in just these few bits of conversation! I'll plan on trashing this when it's done, and be ready to buy some new buckets lol :laugh: I'll keep this post updated as I get to work on the helm a bit more.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 07, 2018, 02:03 PM
Alright it's not much but I made some progress today. I didn't get far because in using my  "dremel" I broke three of the cheap grinding blades that came with it. So I have realized I need to suck it up and get something of a bit higher quality before I progress further.

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

I have removed the rest of the bucket leaving about a quarter inch of space around the outline so that I can come in later and get it more precise and I wanted to make sure I had enough material for adjustments and changes. I also did not remove any of the plastic from the back, I just sliced it up the middle splitting the difference between the two ends of the template.

Below is an image I created of what I want the final product to look like. I'm not 100% on the bottom of the t-visor but I know I want to keep it connected somehow.

(https://i.imgur.com/jHkcdgi.jpg)
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 09, 2018, 08:05 PM
Question for all you experienced guys. How important are internals? by that I mean, mic, hearing aid, fans, etc. I'm trying to keep this budget and so far I'm doing really well, so I was thinking of at least adding fans. I would love to be able to add the audio components too just wondering what time table I should set for those in terms of do I need to get them before I finish my kit or can it be after?
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 09, 2018, 08:41 PM
I still don't have any of that stuff on my helmets.  I do have vents in the earcap design though that help with hearing.  I know plenty of others without fans/audio gear.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 09, 2018, 08:53 PM
Ok that is good to know, I was thinking of cutting some sort of cool vents in the ears and maybe the front of the cheek arch too for hearing and talking.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 10, 2018, 01:42 PM
Well This is where things get interesting, as I had a feeling they would. Below are some pictures of the helmet on my head. I am having some issue with getting it mocked up correctly but I'm not sure how to get it just right.

(https://i.imgur.com/1rfWG4E.jpg)

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

(https://i.imgur.com/2HdLzDs.jpg)

As you might be able to tell the helm sits very very close to my nose, in fact the support bridge (which will be removed) actually touches my nose, squishing it a little. This of course means that a visor would do the same once installed.

I should also note that the hard hat at the front is just barely overlapping the buckets, so I can't really move it up any more.

I have a significant overlap of material in the back of the helmet and I think with some tweaking I might be able to get it right I'm just not sure what adjustment to make.

Here is the bucket flat on the table if that helps, not sure if it does or not.

(https://i.imgur.com/mT69lUt.jpg)

(https://i.imgur.com/7nm2xMM.jpg)

I would appreciate any advice anyone has, I don't want to progress without some help of what I can try, or just let me know now if I'd be better off just getting a couple more buckets.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 10, 2018, 03:07 PM
To get more nose clearance, you could cut a strip of bucket plastic to act as a spacer between your current brow ridge and the hard hat. The problem you're hitting is why I wound up making a custom dome out of bucket, but I needed another inch or inch and a half of clearance, not a few mm.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 10, 2018, 03:25 PM
Got it, what an easy fix haha I didn't even think about. That's why we have you pro's  :D I will give that a shot and see how it goes.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 10, 2018, 06:48 PM
Quote
That's why we have you pro's

I just make all this stuff up as I go along... ;) Hope it works out for you vod!
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 11, 2018, 07:45 PM
Ha well you're a pro compared to me, made up or not. I will keep this post updated with my advancement.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 19, 2018, 11:51 AM
And another update to the work. It took me a couple of methods to try and get the bucket to sit off my nose.

At first I tried a complete ring as was suggested, but because of the angle of the helmet it did not take properly.

(https://i.imgur.com/bG0aUEJ.jpg)

So I shrunk it down and used more of a shim and that worked perfectly.

(https://i.imgur.com/grYxaA5.jpg)

I also added additional padding. My sons old alphabet floor mat is working perfectly. (he's older now, and I got his permission)

(https://i.imgur.com/V1oj7v6.jpg)

(https://i.imgur.com/BGUK5EN.jpg)


And finally, I have rough sanded everything with 60 grit sand paper, and cut out the cheek parts from 3mm sintra

(https://i.imgur.com/dPlwC5Q.jpg)

(https://i.imgur.com/hHn1JTY.jpg)

So now I return for more opinion and help. Below are the pictures of how it fits now and I need some advice on fit. It is now off my nose and I can see well through the eye's. I think it looks a little short to me but, I can't really tell. It comes down to just past my chin and beard.

(https://i.imgur.com/YPWKYu8.jpg)

(https://i.imgur.com/dLWBZ2U.jpg)

(https://i.imgur.com/GH0y8Qb.jpg)


Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 19, 2018, 12:06 PM
Looks like good progress :) Glad you experimented till you found soething that worked! I've got that same kind of foam in my helmets too. albeit less excitingly colored versions of it.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 19, 2018, 08:46 PM
Me too, I think the combination of both worked really well, and though exciting now I think I will paint the whole interior (foam included) black once I get to that point. Does that look like it is the right length? I don't want it to be too short.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 19, 2018, 10:23 PM
looks good to go, will know for sure when cheeks are in.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 20, 2018, 02:52 PM
Awesome! then I guess the next step is to glue the panels together, permanently mount the dome,  and bend and attach the cheeks. This is where it gets really real, I'm so excited!!!!!
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 20, 2018, 05:06 PM
Cheek installation is the hardest part for sure, but I have faith in you vod! :)  :cookie:
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 30, 2018, 11:36 AM
And it all comes tumbling down.

I'm trying not to be too upset but I'm going to have to get some more buckets and another hard hat. I'm not giving up on this, but if after one more attempt I fail again. I may just save up and buy from a seller.

Several things pictured below compounded to my ultimate failure.

First, after adding the brow ridge to get the visor off my nose I ended up with significant gaps on either side. I thought I could fill those.
(https://i.imgur.com/cr2AELM.jpg)

(https://i.imgur.com/ZhgFZ8p.jpg)

but then after securing the sides I realized I shorted myself about a 1/4" of material and had a gap in the back of the bucket (this was the case for both layers) and did not have a even matchup top to bottom either.

(https://i.imgur.com/uKHiN1s.jpg)

and finally Thinking I could over come those two things with some handy work. I began to grind down the screws and in my haste and not paying attention, I melted two large holes in my helmet, both the dome and the face.

(https://i.imgur.com/XkLDZP7.jpg)

All of these events compounded to my giving up on this attempt. I think I will start a second WIP for that but I'm not sure.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 30, 2018, 03:19 PM
Sorry to see that! I didn't think about it changing things in the back.  But now you know the challenges you need to overcome in advance, so 2.0/3.0 should be all the better for it!

Continue it here so others can learn :)   All of my failures are in the same Wip that lead to my successful homer bucket :)
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Jul 30, 2018, 04:09 PM
Will do. The other I noticed is that the full templates for the helmets create a much more round helmet where the hard hat I bought was much more oval. I think I will either adjust the template or buy a more circular hard hat this time around as well.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Jul 30, 2018, 04:16 PM
What I've discovered through successive builds is that my head is much more oval than round (esp. with glasses factored in) -- everybody's different.  The round may end up just being wasted space on the left to right.
Title: Re: Homer bucket First Attempt WIP
Post by: Kurshi BeJahaal on Aug 01, 2018, 10:07 PM
Sorry to see that! I didn't think about it changing things in the back.  But now you know the challenges you need to overcome in advance, so 2.0/3.0 should be all the better for it!

Continue it here so others can learn :)   All of my failures are in the same Wip that lead to my successful homer bucket :)

My successes and failures are all logged in my scratchbuild bucket WIP also haha.
I'm bummed to see that this didn't work out exactly. But here are a few thoughts. Hopefully it's not too late to consider a few of them!  :)

 
1.) Mine was too short in the back as well. I cut it to have about a 2 or 2.5" gap and added a piece to fill it. Then I used quiksteel to bond the two layers together. You can always do that and add another layer behind them so that it overlaps all of the separated pieces. It'll be nicely reinforced then!

2.) If you want to round out your hard hat a little, heat it with a heat gun and sandwich it between two heavy objects. I opted for the couch and the wall. I put just enough pressure on it to adjust the shape slightly and left it sit to cool overnight. Once you take it out, check to see that it holds shape. You may need to do it again.

3.) If you have gaps, you can always back the screws out and drill it again after you tighten it up a little. The holes that you have left will be able to be filled with bondo or spot glaze putty.

4.) I made sure that I used quiksteel to secure my hard hat to the bucket part and let everything cure. Once I was sure that the bond was strong enough, I backed the screws out and filled those holes in too. I never thought about the heat transferring to the plastic and melting the area around the screw.  :o
Title: Re: Homer bucket First Attempt WIP
Post by: Jag Cabur on Aug 03, 2018, 10:16 PM
Ouch.  I came up short like that for my first helmet, but I elected to bolt on an extra plate to connect the two halves instead.  Considering how it turned out, I'm not sure it was the right idea or not.
Title: Re: Homer bucket First Attempt WIP
Post by: Bowfanny on Aug 04, 2018, 02:47 AM
The gap happens when folks donít account for material thickness. Paper is one thing but adding additional length to the templatesto account for the thickness of the buckets is essential, otherwise you get gaps.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Aug 04, 2018, 10:53 AM
My successes and failures are all logged in my scratchbuild bucket WIP also haha.
I'm bummed to see that this didn't work out exactly. But here are a few thoughts. Hopefully it's not too late to consider a few of them!  :)

 
1.) Mine was too short in the back as well. I cut it to have about a 2 or 2.5" gap and added a piece to fill it. Then I used quiksteel to bond the two layers together. You can always do that and add another layer behind them so that it overlaps all of the separated pieces. It'll be nicely reinforced then!

2.) If you want to round out your hard hat a little, heat it with a heat gun and sandwich it between two heavy objects. I opted for the couch and the wall. I put just enough pressure on it to adjust the shape slightly and left it sit to cool overnight. Once you take it out, check to see that it holds shape. You may need to do it again.

3.) If you have gaps, you can always back the screws out and drill it again after you tighten it up a little. The holes that you have left will be able to be filled with bondo or spot glaze putty.

4.) I made sure that I used quiksteel to secure my hard hat to the bucket part and let everything cure. Once I was sure that the bond was strong enough, I backed the screws out and filled those holes in too. I never thought about the heat transferring to the plastic and melting the area around the screw.  :o

Thank you all for the advice, I think I just got overwhelmed when all those things came down in one day. I will see what I can do to make it work, I'm also saving up some cash just in case I can't save it.
Title: Re: Homer bucket First Attempt WIP
Post by: Kurshi BeJahaal on Aug 05, 2018, 05:21 PM
I saw that you had called Dibs on a bucket in the trading station. If you can snag it for that price, I'd say go for it too!
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Aug 05, 2018, 08:59 PM
It was too small, thankfully he measured it up before finalizing the sale.

I've been thinking now for a couple days as I cut armor templates and other such things.

Since I already know that I'm short around the back, I think if I add in some spacers on the side of the  dome that drop down internally so that I have something solid to attach to with the epoxy. That will solve my screw melting issue and round out the helmet diminishing the gaps and equalizing them uniformly around the circumference. Then I can place a filler piece on the back side to close the back up nicely and hopefully I can recover my bucket.

What do you guys think about that? any other suggestions?
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Aug 26, 2018, 06:52 PM
OK I'm back up on the horse, after going to an AP and talking with some of the OM's in my clan I got through my defeat and I have a small update.

So after the melting and gapping issue I resolved to have a larger brow look. I then proceeded to add tabs that dropped down off the hard hat to give me more purchase space to glue the face mask on. I am using some E6000 which is a 24 hr cure so the process is still going but here are some of the images of what I have done. It may not look like much but this is huge progress to me.

Here the tab is glued to the hard hat but not to the mask yet.

(https://i.imgur.com/KkmT7V3.jpg)

Here you can barely see but the mask is glued to the tab and clamped in place to prevent sliding.

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

So that is where I am at right now. Once I get the rest of the tabs glued to the mask I will fill the large gap that remains between to hard hat and mask with plumbers epoxy to fill it and give it some more surface contact. And then on the back I will have to carefully cut and fit a piece to fill the gap and work out the smoothing and shaping of the back of the bucket in the bondo and sanding phase.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Sep 05, 2018, 05:44 PM
A small but important update on forward thinking an planning. I reached a stumbling block again when I realized the depth of the back of the face mask exceeded the depth of the clamps I had, and also most any clamp that I could find. So I used a ratchet strap to clamp it down near the top.

(https://i.imgur.com/EPI6tLY.jpg)

So I finally have the first major gluing and clamping done I am letting it cure extra long because of the weather here. But hopefully I can glue down the second part helmet sometime next week when I get the chance ( and hopefully a break from the heat).
Title: Re: Homer bucket First Attempt WIP
Post by: Bowfanny on Sep 05, 2018, 07:36 PM
Good outside the Buyíce thinking!
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Sep 05, 2018, 09:12 PM
THank Bow, I have a lot more of that type of thinking staring me in the face but I'll get through it and my Buy'ce will be all the more special for it.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Sep 18, 2018, 03:40 PM
Forgive if this is double post. I believe the rule is within 24 hours and this is beyond that. but please fix if needed.

Guys the stressful part is over!!! I have finally gotten my bucket all glued together and it actually seems pretty solid. I'm still going to reinforce it I have plumbers putty to jam in the gaps that I have and I think I may buy a healthy amount of epoxy (30 minute) to really back up the plastic.

But enough talk here she is in all her unfinished glory!

(https://i.imgur.com/pIAYv8m.jpg)

(https://i.imgur.com/aLAA88x.jpg)

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

Its not perfectly even but I can fix all that. I have already glued another brace at the back on the bottom that is drying and then I start to fill all the gaps and sand her down.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Sep 18, 2018, 04:07 PM
Photo links are broken, glad you're making progress vod!
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Sep 19, 2018, 07:37 AM
should be fixed now, I forgot I changed the pictures a little
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Sep 19, 2018, 11:31 AM
Great progress :)
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Sep 20, 2018, 09:07 AM
Thank you Sep. So I was thinking and would love some input. On the back I need key slots. I plan to make those out of sintra, should I fill and sculpt the back first or make the cut out first? I know doing the cut out would Save me the time and work, But if I fill and sculpt it first, I can shape the sintra more accurately to the back of the bucket. Just not sure which approach is better.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Sep 20, 2018, 01:56 PM
Whatever you do, before you cut a square out of the middle, do something to brace the bottom so it doesn't warp.  I'm not sure what would be best, since my Bucket from a Bucket build didn't include keyslots.  I just left it flat there. 
Title: Re: Homer bucket First Attempt WIP
Post by: Bowfanny on Sep 20, 2018, 07:33 PM
Brace the bottom like Sep said,
Measure it out a couple times and then shape the sintra/foamex to the opening.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 11, 2018, 05:43 PM
Alright time for a big, big update! I am now about 95% of the way done! I have key slots (thanks to the sacrifice of a broken fan!) and cheeks!

First the fan, It's been sitting in the garage and collecting dust, I brought it out so I could use it for greeblies and I was totally stuck on the key slots and getting it right but not having huge holes in the back of my helmet when inspiration struck.

(https://i.imgur.com/YF5IL11.jpg)

(https://i.imgur.com/cZJ006j.jpg)

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

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

I was able to trace inside each rectangle and cut out the key holes individually allowing me to keep some strength and structure to the back of the bucket.

Then came the hard part! The cheek and face plates. I apologize for the lack of photographic evidence but take my word, I spent 8 hours over two days prototyping and fitting and bending and redoing the cheeks. I went through I think two card board boxes (my practice and templates) and a 1 x 2 ft piece of sintra trying to get the fit right. Now it's not perfect by any means  and I still have a lot of sanding and filling (and sanding and filling) in my future to get these things to look good and then some sanding and filling before I'm done. But this is still big progress and here are the photos.

(https://i.imgur.com/yfQ6jdN.jpg)

(https://i.imgur.com/4Tmg293.jpg)

(https://i.imgur.com/vhQCD2R.jpg)

Again there were moments of inspiration here. I used the leftover cheek cut outs from the bucket for the inner plate by sheer accident. I was having so much trouble getting the bend right and by chance I just picked it up and checked the fit and boom, it was perfect!
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 11, 2018, 07:36 PM
Great idea for the key slots! :) Looking good, cheeks are hard!
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 12, 2018, 05:30 PM
Cheeks are really hard, that compound curve is tough to hit. I finally accepted the closest I could get and I will have a lot of filling and sanding to do to get the final shape proper. I also used a lot of hot glue (since it's flexible and it sets quickly) so I will have to come in behind and replace that with epoxy so that my face doesn't melt off if I get too hot lol.
Title: Re: Homer bucket First Attempt WIP
Post by: Havelock on Oct 15, 2018, 05:15 PM
This is coming along very nicely!  Great find for your keyslots.  You might need to back that with a fine mesh, to prevent people being able to see the back of your head, but definitely a great use for that fan.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 15, 2018, 05:46 PM
Thanks Hav! I will be wearing a Balaclava for my kit, would that be enough or would I need something right on the inside of the helmet?
Title: Re: Homer bucket First Attempt WIP
Post by: Havelock on Oct 15, 2018, 09:52 PM
If you're going with a balaclava, you're good.   ;D

Edit:

Or what Bowfanny's about to say.
Title: Re: Homer bucket First Attempt WIP
Post by: Bowfanny on Oct 15, 2018, 09:53 PM
Thanks Hav! I will be wearing a Balaclava for my kit, would that be enough or would I need something right on the inside of the helmet?
Youíll want the mesh in the helmet itself as not having it makes the finished helmet look like itís unfinished. Even when painted it will just look like itís missing substance.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 15, 2018, 09:56 PM
OK cool not a problem. I'm sure I've got something laying around
Title: Re: Homer bucket First Attempt WIP
Post by: Bowfanny on Oct 16, 2018, 12:05 AM
OK cool not a problem. I'm sure I've got something laying around
Iíve used spare window mesh that I had laying around from a home improvement project I did. Scraps are awesome.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 16, 2018, 12:15 AM
I used black pantyhose on mine.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 17, 2018, 05:12 PM
Ok thanks for the advice on that guys. I got some more work done today, mostly sanding so no pictures to really show. But I sanded down the whole helmet to 120 grit, sanded down the insides of the cheeks so I had some more room, carved out a ton of the hot glue and replaced it with 5 min epoxy for a stronger more weather resistant adhesion. I also cut out the top of the two braces I had in the T part of the visor, I have decided to leave the bottom one for more stability.

Question I posted on my WIP but not here. Does anyone have a reliable way of segregating the heat on sintra? I want the cheeks to be a bit shallower but obviously don't want to lose the curve I have or the adhesion that is still partially hot glue. I'm not sure I dare to even try it but I thought I would ask to see if anyone had a method for such a thing.

I plan to move on to Bondo tomorrow any advice for a newbie like me?
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 17, 2018, 08:06 PM
you could try submerging the parts you don't want to heat up in cold water.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 17, 2018, 08:16 PM
So here is a pic of what I need to do, it may not even be possible. Anything above the black line I need to keep cool, below is what I need to heat up and pull down and out so I have a little more space inside.

(https://i.imgur.com/kxB1XgP.jpg?1)

Would it be better to just redo the cheeks entirely? If so that is something I'm willing to do after Halloween is over lol
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 17, 2018, 09:27 PM
It looks to me like you'd need to cut a dart to get what you're wanting... so probably easier to just redo the cheeks completely.
Title: Re: Homer bucket First Attempt WIP
Post by: Kurshi BeJahaal on Oct 17, 2018, 10:00 PM
Woah! You've made a lot of progress on this! I'm disappointed that we don't have this Sunday available anymore to make some more progress on it!
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 19, 2018, 05:14 PM
Yeah man I've been busting my butt on it lately thanks for noticing! I'm so bummed that the 21st got spoiled, I was really planning on using that time to cut my plates and get sizing and shaping right. I'm definitely going to do my best to make the 28th but that is going to be really tough.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 24, 2018, 10:40 AM
I've got a question for you experienced Buy'ce builders. When Bondo-ing do you just slather the helmet completely or is there a method, or stages that you do it in? I did some touch up Bondo on the helmet to fill in my major gaps and square up some of the not so square parts but I was hesitant to just slather it everywhere in case that wasn't the right procedure.
Title: Re: Homer bucket First Attempt WIP
Post by: Arkham on Oct 25, 2018, 08:12 AM
I would suggest using thin coats on smaller sections of you helmet. For instance; you might do 1/4-1/2 the dome, or just the visor/brow ridge area, or one cheek. The bondo set pretty fast, so if you try to do large areas, it will set before you get it all applied. As you're going to be sanding A LOT anyway, you're better off sanding several layers of thin coats, trying to power through a thick one. This also let you fix small imperfections in a previously sanded area, while applying more bondo to a new area of your helmet.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 30, 2018, 01:47 PM
Ok so I had a party to go to last week and I threw a quick version of a mando together. No weathering or anything. My helmet isn't done but I put in a quick visor and let it be what it is for now. In my rush though I only sanded to 80 grit and obviously when I painted it was really rough. So I came home and stripped the bucket and resanded it down to 1000 grit. However I still have the same issue. It seems that little flaps or tags of plastic get lifted or flattened but not removed from the helmet.

Here is what it looks like now after being sanded to 1000 grit:

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

any ideas how to solve this issue for when I really go after the real paint job?
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 30, 2018, 02:00 PM
it looks like it's only on the hardhat... did you sand the hardhat/bondo to a high grit before painting, or just the paint on top of it?
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 30, 2018, 02:08 PM
Yeah it is just the hard hat. So the whole process was I bondo-ed some of the problem areas like the injection point at the top of the dome and other spots. Then Bondo-ed the whole dome (realized I wouldn't have that done in time for when I needed it) sanded the whole dome to strip the bondo. Painted it the first time. Stripped that and sanded it to 80 grit, then to 120 grit, then to 400, then to 1000. That picture is plain hardhat no bondo after being sanded to 1000 grit.
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 30, 2018, 02:12 PM
You might try sanding the paint back off the hardhat, then taking one of those long grill lighters to the furry bits... it might not work though, and definitely odn't keep it there too long if it isn't.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Oct 30, 2018, 02:18 PM
Oh good idea I hadn't thought about burning/melting them off. Well I have a halloween event tomorrow but after that I will definitely try that. Thanks Sep you truly are a helmet master!
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 30, 2018, 02:22 PM
I just make it all up as I go along -- if it fails, we'll try another thing ;)
Title: Re: Homer bucket First Attempt WIP
Post by: Kurshi BeJahaal on Oct 31, 2018, 05:43 PM
So it's like a slight "fuzzy" feeling?

Would wet sanding with a fine grit help with that at all Sep?
Title: Re: Homer bucket First Attempt WIP
Post by: Sep Ho'ban on Oct 31, 2018, 05:49 PM
He said he's already tried it, so I don't know. There's a lot of trial and error, cause those hard hats aren't manufactured with the intent of someone painting them.
Title: Re: Homer bucket First Attempt WIP
Post by: Kurshi BeJahaal on Oct 31, 2018, 05:58 PM
I missed that part. Oops!

hmm...

I'm also wondering if hitting it with some Primer/filler, then light sanding, Primer/filler, light sanding (and repeat as necessary) would help? I've encountered the "fuzzy plastic" issue and done that with some really, really fine grade sandpaper and it's seemed to work out decently for me.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Nov 01, 2018, 04:54 PM
Thanks for the idea Kurshi! I will be stripping the whole helmet probably on Monday. I will try the lighter trick first and if that doesn't work then I will try the prime and sand method.
Title: Re: Homer bucket First Attempt WIP
Post by: Kall on Nov 03, 2018, 11:19 PM
Really liking how this is coming along. Keep going Vod. :like:
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Nov 04, 2018, 10:19 PM
Thanks Kall! I still feel like I've got a really long way to go but I appreciate the encouragement
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Nov 09, 2018, 04:00 PM
Alright well I knew this day was coming, I put it off almost a full week. I knew that I would be replacing the cheeks and I knew that I would be stripping the paint but it was really hard to actually do lol. But I've started and here is what I have in terms of photos.

(https://i.imgur.com/G7euVX0.jpg)

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

I'm using nail polish remover to soften up and remove some of the paint and then using a metal scraper (razor blade) to remove the bulk of the paint. From what I read any real paint remover would be too strong and likely destroy the plastic underneath so it is a slow and steady process. I got half the dome done in about an hour.
Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Dec 09, 2018, 09:22 AM
A little bit of an update here I have modeled some custom Ear carps that I hope to print, we'll see how that all goes. And then I have stripped the rest of my helmet back down to plastic so I can sand it properly,  redo the cheeks, and paint it properly.

The right ear has some knobs and inserts for "antenna" (I plan on using Bic pens I stole from work):

(https://i.imgur.com/R4d0O0p.jpg)

(https://i.imgur.com/ezWw1iD.jpg)

(https://i.imgur.com/yAsxI5V.jpg)

(https://i.imgur.com/cPuaPq1.jpg)

And the stripped helmet, not much to look at:

(https://i.imgur.com/pQfit49.jpg)

(https://i.imgur.com/P072qdg.jpg)

Title: Re: Homer bucket First Attempt WIP
Post by: Ko'rizna Falco on Mar 15, 2019, 03:37 PM
Ha resurrecting to show some progress, winter did me in hard lol (yay for outdoor shop in cold weather).

I didn't get much done but I got things lined up and secured on the cheek in preparation of the big bend and complex curve.

(https://i.imgur.com/a90EuUQ.jpg)

(https://i.imgur.com/MFs1qzN.jpg)