Mandalorian Mercs Costume Club

Mandalorian Armor => Helmets => Topic started by: Kebii'tra Verda on Aug 22, 2009, 07:23 PM

Title: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Aug 22, 2009, 07:23 PM
EDIT: 10-16-2015 It has been over 6 years since I made this bucket. I have received several messages asking about this project, and while I have been entertaining the idea to create a new thread that is updated, it may be a little while until that is done.

EDIT: 2-4-2018 To anyone asking, I no longer make the dome I used for this helmet. That was part of a failed vac-form helmet project from LOOOOOONG ago. The templates for the W.O.F. dome can be found in the TEMPLATES section as part of the patterns I used to make this helmet, or you can use a bike helmet, hard hat, etc.

No, not Homer Simpson, Homer from Home Depot!

A while back I picked up some buckets from Home Depot for the purpose of seeing if I could make a good helmet out of them. I think it worked...
For both inner and outer shells, make the templates wrap around the bucket with only one seem in the back. Flip the bucket over, bottom side up, to make your marks and cuts.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0012.jpg)
You will have a little piece left over. Cut it out and use it as the scab connector in the back.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0013.jpg)
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0014.jpg)
On the outer shell, trace out the cheeks, visor, and back and cut. Lay this piece on the inner shell to make guide lines for the glue.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0015.jpg)
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0016.jpg)
After the glue has set, cut out the cheeks from the inner shell .
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0017.jpg)
Make the cheeks from Sintra and add a Mandalorian Arsenal dome. (Shameless plug... ;)) dome I no longer make.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0018.jpg)
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0019.jpg)
Lay down two to three coats of Krylon for Plastic, letting each coat dry thoroughly before proceeding.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0020.jpg)
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0021.jpg)
I used Smoke Gray as the main color, and the Jango Light Blue for the ears and cheeks. For these ears, I fashioned them out of Sintra...
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0023.jpg)
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0024.jpg)
...and bolted them on. For the right ear, I simply flipped the pattern to make a mirror image.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0025.jpg)
Cut out for the visor (the bottom section WILL come out later)...
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0026.jpg)
...and paint the clan sigil on the forehead.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0070.jpg)
Plus, for now I cheated. I'm using MS Paint for the visor.

That's it for this helmet. It really was that simple. But, as I mentioned in the Official Clone Wars Mando thread, I will be sacrificing this bucket to turn it into molds for a helmet run. I've had so many requests for helmets that I think the time will be right a lot sooner than I had planned. I'm still going to make the armor, as planned, but this bucket will be going under the knife soon after that.

Enjoy!

david.






Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Corr Ordo on Oct 01, 2009, 10:44 PM
*poke* Updates, sir? :)
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: TrooperJasher on Oct 01, 2009, 11:39 PM
great start, any new updates?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Oct 02, 2009, 04:53 AM
Not really. This was just a simple tutorial to show how you can use 5-gallon buckets to make a helmet. All it needs is a real visor, but that's been covered in other threads. If I do eventually turn this into a mold for casting, I'll probably start a thread in the Trading Station.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Synnr Falco on Oct 02, 2009, 10:42 AM

What do you use to cut the buckets?  I've been doing most of my cutting of sintra with a fresh utility knife. But I think I curved surface like that wouldn't work to well.  jigsaw? sawzall?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Oct 02, 2009, 12:05 PM
Rotary tool with the cutting disk finished off with the sanding drum.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Taxtro Duo on Oct 02, 2009, 12:30 PM
Hey David, how this bucket helm, fit someone with a bigger head? This is my problem with all my buckets/helms, they barely fit due to the largeness of my noggin.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Oct 02, 2009, 02:01 PM
Well, this one was made like my others with the WOF patterns. If you have a larger size head, just scale the drawings up to a size you are comfortable with.

Here's the easiest way to do it: Measure around your head at the temples. Take that number and divide it by pi (3.14). You do this because you are looking for the diameter of your head. You find the circumference of a circle by using the formula pi x D, so reverse that to find the diameter. Take the number you get, round up, and add 1 inch from side to side and 2 inches from front to back. This is because the dome of the helm is not a true circle. Now, print out the pages with the dome base pattern (page 9 and 10) and put it together. Find the difference between the front/back and side/side measurements from the pattern versus what you measured out. Divide the numbers to get the percentage of increase and use that to scale your patterns.

It sounds complicated, but trust me, it's not. ;)

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Dar'manda on Oct 02, 2009, 02:40 PM
Well, this one was made like my others with the WOF patterns. If you have a larger size head, just scale the drawings up to a size you are comfortable with.

Here's the easiest way to do it: Measure around your head at the temples. Take that number and divide it by pi (3.14). You do this because you are looking for the diameter of your head. You find the circumference of a circle by using the formula pi x D, so reverse that to find the diameter. Take the number you get, round up, and add 1 inch from side to side and 2 inches from front to back. This is because the dome of the helm is not a true circle. Now, print out the pages with the dome base pattern (page 9 and 10) and put it together. Find the difference between the front/back and side/side measurements from the pattern versus what you measured out. Divide the numbers to get the percentage of increase and use that to scale your patterns.

It sounds complicated, but trust me, it's not. ;)

David.

I couldn't understand this at all, but the wife seems to, so i'll have her do the math! :D
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: E'nam Atreuh on Oct 04, 2009, 07:14 PM
Nice a fellow Nole' s fan! good bucket  (no pun)
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Oct 04, 2009, 07:33 PM
For this one I used Locktite Waterproof Adhesive. I don't like it as much as the last tube of contact cement I had which works a lot better, but I needed some quickly and this was the only comparable thing on the shelf.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Dar'manda on Oct 04, 2009, 07:34 PM
So, the last tube you had that you DID like was?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Oct 28, 2009, 01:29 PM
That would be a red tube of something called "Welder." I'm still trying to locate more and when I do, I may buy out the stock. ;)

Okay, another step towards making copies of this thing. I took the advice of some people and worked on making the sides more narrow. Basically, what I did was attach some temporary braces from side to side to make it hold a narrower shape.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0064.jpg)
Ignore the white pieces of sintra in the visor area, that's to hold the top of the mandables in line with the brow. And here's a comparison (if you can see the difference) between a Rubies (Jauri's), the CW, and my own scratchbuilt.
(http://themandalorianarsenal.com/images/OldStuffForMercs/Homer%20SANY0062.jpg)

For those curious about the measurements, it's roughly 8 1/2 inches (21.5cm) from inside ear to ear and 10 1/4 inches (26cm) front to back.

I will hopefully be able to do more after the first of the year once I get my student loan. :) (And yes, that includes the other things I need to finish up on. Some of you know what I'm talking about. ;))

David.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Squirrel on Oct 28, 2009, 04:20 PM
I want one. It looks good. how crisp are the seams?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Oct 28, 2009, 05:16 PM
Keep in mind, this is just the prototype. I still have to make the initial negative mold then the final positive, plus finite touch ups. It will take a while, but my plan is to have the seam from the rear half rest under the front half with only minimal seamage right next to the ears.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Dar'manda on Oct 30, 2009, 08:05 PM
I guess i'll trundle over to home depot and thunk this Homer bucket down over my head and see if it fits... As long as it does, i'll be in business.. What would you suggest making the dome out of, since I lack one of your fine pre-made ones?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Oct 30, 2009, 11:37 PM
You could use just about anything. A batter's helmet seems to be one of the best options. I do plan on making more domes, but probably not until after the first of the year.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: jatne on Feb 25, 2010, 09:07 PM
looks good Ive been meaning to make myself a helmet so helpful tips
 :) :) :)
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Ha'sid on Feb 26, 2010, 01:31 AM
Any estimated price range for the premade one or what do you think about selling the proto type after its cleaned up and negatived?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Xyon Koreen on Feb 26, 2010, 01:47 AM
okay how much for one of these mandalorian arsenal domes????  when i get my pennies saved i might attempt to make one for zarah or another for myself as a new color scheme
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Jaing Vau on Feb 26, 2010, 06:03 AM
Cool man! Can't wait for you to slap a visor on that shabuir!
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Feb 26, 2010, 07:01 AM
Any estimated price range for the premade one or what do you think about selling the proto type after its cleaned up and negatived?

No thoughts on selling this one because I'm probably going to cut it up to make molds. I haven't firmly decided on that plan yet, but I am thinking about it. Price range - if you make it yourself, you're looking at about $10+ for two buckets and (I think) about $5-10 for a sheet of sintra for the cheeks. The dome is the kicker...

okay how much for one of these mandalorian arsenal domes????  when i get my pennies saved i might attempt to make one for zarah or another for myself as a new color scheme

I was charging $40 shipped when I was selling them. Add this to what I said above, you're looking at $60+- for all the plastic, plus whatever you want for paint and a visor.

If I do go ahead with making this into a mold, I plan on forcing it to be more narrow on the sides to be kind of a hybrid between real-world and CW toon bucket. PLEASE DON'T ASK ME FOR A PRICE YET!!! ;) ;) ;) I haven't even gone down that road to figure out what I would charge for a full bucket.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Captnrex on Feb 26, 2010, 07:33 AM
can we ask now? lol

Helmet looks awesome btw ;D
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: SnakeEyes1 on Mar 13, 2010, 04:54 PM
My question is the round dome for the top you never showed how to make it
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Mar 13, 2010, 05:09 PM
I have a mold that I'm working on fixing up right now. I made it using the WOF pattern then vac-formed it using 2mm Sintra. Once I get it reworked, I'll use it as part of this kit.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Riya Morut on Apr 02, 2010, 01:06 PM
Hey David, could you show how you bolted on the ears? 
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Apr 02, 2010, 02:30 PM
It's more telling than showing. Basically, you make the ears, draw the outline on the bucket (lightly with a pencil), figure out the centerline and where you want the bolts. Drill out the holes for the bolts and tape on the ears. Mark from the inside out on the back side of the ears where the bolts will go. Take the ears back off and line up the bolts. Trim out a hole for the bolt head and secure it in place with glue (preferably epoxy or something as strong). Wait for the glue to dry then mount the ears.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Noah Nei on Apr 27, 2010, 06:57 PM
Okay I have a quick question...is this better than buying a helmet and painting it???
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Apr 27, 2010, 11:54 PM
I wouldn't say better, per se. Just different. I did this for two reasons. 1) To try it for myself and show a different method of making a helmet and 2) to make something I could use as a mold for mass production.

Having done that. I can say that while it's a different method, it may not suit some people, depending on their personal construction skills.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Squirrel on Apr 30, 2010, 08:07 PM
So any major progress?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on May 02, 2010, 07:35 AM
http://mandalorianmercs.org/forum/index.php?topic=24643.0

I'm going to go ahead and lock this thread simply because there isn't anything new to add to this construction process, and because the other thread shows the continuing progress.

David.
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Toonz on Dec 12, 2017, 01:17 PM
where can I find the printable templates for the bucket helmet build?
Title: Re: Clone Wars Mandalorian Helmet - Homer-Style!
Post by: Kebii'tra Verda on Dec 12, 2017, 02:15 PM
where can I find the printable templates for the bucket helmet build?

Here's the thread: http://mandalorianmercs.org/forum/index.php?topic=109722.0
and this is the direct link: https://onedrive.live.com/?authkey=%21AImBk83WCpgNVDY&id=5BC322B9AE9A1C55%21632&cid=5BC322B9AE9A1C55