Mandalorian Mercs Costume Club

Mandalorian Armor => Helmets => Topic started by: Bfahome on Sep 18, 2015, 09:14 PM

Title: Bfa's WOF template build attempt
Post by: Bfahome on Sep 18, 2015, 09:14 PM
Hi!

I may not be the biggest Star Wars fan, but I do like it and I think the Mandalorian armor design is pretty cool, so I decided to try and make a helmet at the very least.  Also I just like trying to make (http://www.bzpower.com/board/uploads/blog-0571032001396201394.jpg) things (http://www.brickshelf.com/cgi-bin/gallery.cgi?f=530355).

(http://i.imgur.com/moijQZj.jpg)
This is what I have done so far.  It's made of chipboard and some cardstock.  The only purely cardstock pieces are the cheekbone sections, the dome is chipboard covered by cardstock.  I made these choices for the sake of convenience and ease of assembly.

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/helmet1.jpg)
This was my first attempt, but due to poor planning the shape didn't come out right and the dome looked all wonky.  So I abandoned it and started the new one.

(http://i.imgur.com/mwQcq3I.jpg)
I'm at the point with the earpieces, and I'm trying a couple of different techniques.  The first was the same technique used by AntMan in his thread on TDH, but I'm running out of chipboard and I apparently don't have his hobby knife skills, so I'm trying some wood pieces instead.  Luckily I work at a place with a wood shop and plenty of scrap!

I'm not going for screen accuracy or character replication, but for a custom bucket to call my own, so I'll probably be diverging from the actual templates in a few places.

Once I finish the chipboard and cardstock base I'll be coating it in fiberglass resin, filling parts of the inside with Bondo, and shaping it from there.  Then I guess I'll decide what colors i want to paint it and figure out the electronics.  I want a servo-controlled rangefinder with controllable LEDs.  I've already cut and folded the RF from the WOF template and I've used AntMan's three-layer stalk design with the cut-out wire channel, but I don't know if I'm going to be sticking with that design or changing it, since it depends on what I do with the ears.  Time will tell!
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Sep 18, 2015, 10:35 PM
FAKE GASP!! Diverge from the cookie cutter is perfectly fine vod, make that helmet your own creation! In addition I'd say keep the bondo stuff for shaping the outside and just coat the inside with resin and fiberglass cloth. Light amounts of sanding after the resin cures on the cloth make it less poke you in the head type stuff! I also think that your first attempt if you still have it could be a perfectly good helmet with time and patience.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 18, 2015, 11:42 PM
FAKE GASP!! Diverge from the cookie cutter is perfectly fine vod, make that helmet your own creation! In addition I'd say keep the bondo stuff for shaping the outside and just coat the inside with resin and fiberglass cloth. Light amounts of sanding after the resin cures on the cloth make it less poke you in the head type stuff! I also think that your first attempt if you still have it could be a perfectly good helmet with time and patience.
The plan was to do something like I did here (http://www.brickshelf.com/gallery/B-f-a-home/Kumo/151071_494693667237783_2052896255_n.jpg), which was to slosh around a Bondo/resin mix inside the structure to fill it fairly evenly.  I was only going to have a thin structural layer inside, with maybe a bit more at the crown, to make sure I can shape it without worrying about sanding any holes in the dome.  It's worked for me before, but if there's a specific kind of fiberglass that works just as well then I can definitely try that.

(I've helped my then-roommate fiberglass a papercraft costume before, and neither of us liked it, which is why for our future projects we used the Bondo/resin mix as structural filler.)

I don't currently plan on trying to salvage the initial attempt, since I'm still a novice and I've had projects turn out sub-par before because I didn't give them enough care in the start.  I'll still keep it just in case, though.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Sep 19, 2015, 01:29 AM
The plan was to do something like I did here (http://www.brickshelf.com/gallery/B-f-a-home/Kumo/151071_494693667237783_2052896255_n.jpg), which was to slosh around a Bondo/resin mix inside the structure to fill it fairly evenly.  I was only going to have a thin structural layer inside, with maybe a bit more at the crown, to make sure I can shape it without worrying about sanding any holes in the dome.  It's worked for me before, but if there's a specific kind of fiberglass that works just as well then I can definitely try that.

(I've helped my then-roommate fiberglass a papercraft costume before, and neither of us liked it, which is why for our future projects we used the Bondo/resin mix as structural filler.)

I don't currently plan on trying to salvage the initial attempt, since I'm still a novice and I've had projects turn out sub-par before because I didn't give them enough care in the start.  I'll still keep it just in case, though.
Your gonna use Rondo(Resin-Bondo) and its okay for a quick set solution (I've done it a whole bunch) but it's always good to have at least one layer of fiberglass cloth inside the helmet to give it strength. I've shattered rondo before and the same trick doesn't work anywhere near as effectively when the fiberglass is in there. Also when you resin the outside( I recommend it) try not to sand through the resin layer or you could end up with the paper separating from the inside materials which can screw up your whole process because it creates a low spot when they pop off when you're sanding other areas. I'm around if you want any more pointers. I've built 30 helmets of different types now so I know a little of what I'm saying. ;D
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 19, 2015, 02:38 AM
Your gonna use Rondo(Resin-Bondo) and its okay for a quick set solution (I've done it a whole bunch) but it's always good to have at least one layer of fiberglass cloth inside the helmet to give it strength. I've shattered rondo before and the same trick doesn't work anywhere near as effectively when the fiberglass is in there. Also when you resin the outside( I recommend it) try not to sand through the resin layer or you could end up with the paper separating from the inside materials which can screw up your whole process because it creates a low spot when they pop off when you're sanding other areas. I'm around if you want any more pointers. I've built 30 helmets of different types now so I know a little of what I'm saying. ;D
Yeah, I wasn't sure that "Rondo" was a widely-used contraction, so I didn't use the word initially.

I'll definitely look into using some fiberglass cloth, then.  Luckily that's something else I might be able to grab from where I work.

I also think I see what you're saying about Bondo on the outside now, regarding not sanding through the chipboard or paper.  My previous projects were all cardstock, so after the Rondo had set on the inside we'd sand down the outside to get the shape (in some spots sanding away the paper entirely), rather than build up the outside at all.  I'll have to break myself out of that mindset since I'm working with different, and thicker, materials now.

So, new game plan will probably be something like:
- Resin the outside for initial structure and seal
- fiberglass the inside if possible
- apply Bondo to the outside, and sand that to shape rather than sanding the resined chipboard

Basically what I should have learned from the tutorials I read initially but didn't think would be what I did.  Ah well, learning experience. ;D
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Sep 19, 2015, 10:17 AM
Great motivation Vod!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 21, 2015, 05:34 PM
Minor progress on the wooden ear components.  I may redo these, but even as tests I think they look pretty good.

(http://i.imgur.com/8voT4U6.jpg)
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Sep 21, 2015, 07:30 PM
Those look great Vod!
Title: Re: Bfa's WOF template build attempt
Post by: Drako Katora on Sep 21, 2015, 10:56 PM
Ooh wooden Ear caps, that's something I haven't seen. Good work so far!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 24, 2015, 11:01 AM
Okay, looking for some input here: which would be better, attaching the wooden ear caps before resining/filling the helmet, or after?  I assume it's fine to resin the wood directly (attaching the ears, then sealing) but I'd like to be sure before I try anything.

e: Oh, also, are the forehead arrows actually required?  I don't recall seeing anything about those.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Sep 24, 2015, 08:10 PM
Okay, looking for some input here: which would be better, attaching the wooden ear caps before resining/filling the helmet, or after?  I assume it's fine to resin the wood directly (attaching the ears, then sealing) but I'd like to be sure before I try anything.

e: Oh, also, are the forehead arrows actually required?  I don't recall seeing anything about those.
I'd attach the earcaps after resining the rest. Then attach everything once it's smoothed out. Forehead arrows are not required.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 25, 2015, 05:41 PM
Made new earcap pieces today.  Decided against trying to do a nice bevel around the edge because that's haaaaard.

(http://i.imgur.com/b1ZoFsN.jpg)

Ideally I want to be able to swap the RF attachment for a simple antenna attachment, but at the very least I have both options now so even if I can't make a swappable system I can choose which one I want to finalize.

(http://i.imgur.com/hQFJ0Gj.jpg)
Title: Re: Bfa's WOF template build attempt
Post by: Drako Katora on Sep 25, 2015, 08:53 PM
What was wrong with the originals?
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 25, 2015, 11:20 PM
The first set was cut from thinner plywood, so I wanted them to stand out a bit more.  The RF hinge socket plate is the original one, though, since the thinness works there.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 28, 2015, 05:53 PM
First coat of resin!

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/P09-28-15_17.48.jpg)

I've so missed that smell.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Oct 18, 2015, 01:22 AM
Glassed the inside of the helmet this morning.  I'd done a bit of Bondo on the top of it before, but trying to sand it made the helmet deform in a way I didn't like, so I figure I'd make it more rigid first and then work on the shape.  Probably going to sand the excess resin down and then patch up any bits I missed as a next step.  Fun fun!

(http://i.imgur.com/vEGxw4o.jpg)

(It's getting much heavier now. :P)
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Oct 23, 2015, 06:44 PM
Assembled the right ear cap with antennae and installed a potentiometer in it.  Haven't figured out what it'll be used for exactly, but at least it'll look neat, and hopefully like something you'd find on a comm.

(http://i.imgur.com/yconVOH.jpg)
(http://i.imgur.com/4cYH4OW.jpg)

One thing I could use it for is fan control, since I found a laptop cooling pad at Goodwill that had three little fans in it.

(http://i.imgur.com/8exhunI.jpg)

They even light up!

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

I also smoothed down the initial mess of Bondo I had put on the dome, so it's at least something I can work off of now.  Not bothering with a picture of that, since it's not much to look at.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Oct 23, 2015, 06:51 PM
Looking good!
Title: Re: Bfa's WOF template build attempt
Post by: Drako Katora on Oct 26, 2015, 02:21 PM
A bit of warning about the fans. Generally squirrel cage style fans are more appropriate for helmet cooling as you don't have an exposed prop spinning near your face and squirrel cages focus the air more. It's still a matter of preference just thought I'd pass along though
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Oct 28, 2015, 05:40 PM
A bit of warning about the fans. Generally squirrel cage style fans are more appropriate for helmet cooling as you don't have an exposed prop spinning near your face and squirrel cages focus the air more. It's still a matter of preference just thought I'd pass along though
My plan for these fans, so far, is just one or two in the back under the keyslot/vent (not yet cut) to force at least some air circulation.  I'll figure out some way to add a guard to them too, probably.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Nov 06, 2015, 04:49 PM
(http://i.imgur.com/2LklZJ6.jpg)

Where I'm at for the moment.  Initial layer of Bondo sanded down, another layer applied to fix the shape.  Been hitting it with a hair dryer to help it cure, since the weather is now cold and the sun is hiding.

Also ordered some Sintra for armor, that's supposed to get here Monday.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Nov 06, 2015, 04:56 PM
The phase that tests our patience! Sanding and bondo!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Nov 07, 2015, 10:07 PM
Yeah, it's a haul, but I've done similar things before so I know how slow it can be. :P

Anyway, here's roughly what the right ear cap will look like.  I think there'll be a couple of buttons on there too, for electronics reasons.

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

The lower piece will have a row of five little LEDs that'll blink in some pattern, controlled by an Adafruit Trinket (https://www.adafruit.com/products/2000).  The potentiometer will control the pattern somehow, either in speed or brightness, and the buttons will control the pattern and possibly the fans.  The power source will be an Anker portable charger (http://www.amazon.com/Anker-Portable-Technology-Certified-Lightning/dp/B00M8YXV1Q).

e: WIP selfie
(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/wipselfie.jpg)
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Dec 13, 2015, 12:33 AM
You know, I told myself I wasn't going to do a rangefinder for this helmet.  Baby steps, I said, one thing at a time.  I was, of course, lying to myself.

It helps that I had to buy a few 9g servos for a school project, and then realized how well my Trinket fit into the RF end piece.
(http://i.imgur.com/Pj329jX.jpg)
I have some pretty fun ideas about what I might do with this discovery.  I'm thinking of possibly putting the Trinket in the RF for complex light control, and using an Arduino Uno in the helmet itself to drive the servo and control everything.  That way I should only have to run three wires up the RF stalk; two to provide power to the Trinket, and one for serial commands from the Uno.  I'll have to plan further to see what exactly this will allow me to do in the RF, as it'll basically have its own microcontroller at that point.  Was thinking about some number displays or color-shifting LEDs.

(http://i.imgur.com/fwG6OdL.jpg)
I also did some sanding on the dome today, follower by filling some of the more egregious pits with Apoxie Scuplt.  It's slowly taking shape, though still extremely rough around the edges; it's hard to get there with sandpaper, so I'll probably have to take my Dremel to it with some sanding wheels.  Progress is slim, no thanks to the change in weather, though I won't argue with a 50 day mid-December in the northeast. ;D  No lasting snow yet!
Title: Re: Bfa's WOF template build attempt
Post by: Arch on Feb 20, 2016, 08:44 PM
Haha, I haven't seen wooden earcaps before, either! Great idea!
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Feb 20, 2016, 11:24 PM
Haha, I haven't seen wooden earcaps before, either! Great idea!
Wood works great!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Feb 20, 2016, 11:56 PM
I hear a good way to seal wood is a resin + acetone mix, to help it actually penetrate the wood rather than just being on the surface, so that's what my plan is at the moment.

As for the rest of the helmet:

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/phasmaupdate.jpg)

Not much visible change, but I've done a lot of Dremel sanding on the dome with some Apoxie Sculpt spot filling in between.  Also been hitting the crevices around the dome's base with the tool's grinding wheel to clear them up and make them as crisp as possible.  The cheeks, though, need a lot of work that I haven't put into them yet to get the nice sharp lines.  I'll try to shape them with Bondo at some point soon.

Also I've decided against having the Trinket contained in the RF.  It's not too heavy, but it's more weight than I want to put on the servo.  So I'm keeping it in the helmet.  Probably going to use this NeoPixel setup (https://www.adafruit.com/products/2226) in the RF instead, since it'd still only need three wires run up the stalk to work.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Mar 03, 2016, 10:53 PM
(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/cheekybondo.jpg)

Got the Bondo on the cheeks, now waiting for a good day to sand them.

There are also several patches of chipboard that were exposed by all the sanding that I've done, so I'm going to hit those with my next batch of resin along with my other helmet and hopefully my wooden sword blades.  Hopefully I can nab some acetone from one of the labs around campus.
Title: Re: Bfa's WOF template build attempt
Post by: Drako Katora on Mar 07, 2016, 04:52 PM
Have patience with the sanding. Doing a concave face like the cheeks can be maddening, especially if you're trying to get a crisp line where the two faces meet.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Mar 07, 2016, 04:55 PM
Have patience with the sanding. Doing a concave face like the cheeks can be maddening, especially if you're trying to get a crisp line where the two faces meet.
Ditto, if you want to one up your game a good challenge is a Vizsla phase 2 helmet because those cheeks are multi directional!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Mar 07, 2016, 11:50 PM
Have patience with the sanding. Doing a concave face like the cheeks can be maddening, especially if you're trying to get a crisp line where the two faces meet.
i figured it might be.  Hopefully the Dremel should make it slightly easier, like it did for the dome area.

And if not, well, battle damage. :P
Title: Re: Bfa's WOF template build attempt
Post by: Taakur Beroya on Mar 28, 2016, 11:38 AM
The plan was to do something like I did here (http://www.brickshelf.com/gallery/B-f-a-home/Kumo/151071_494693667237783_2052896255_n.jpg),
Oh my god is that a prop Hau :o i'm so jealous right now. First ElJay now you  :-[ I really need to make one  :P
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Apr 02, 2016, 02:39 PM
Yeah. (http://www.brickshelf.com/cgi-bin/gallery.cgi?f=530355)  It's been out of commission for a while though.

Anyway, to give this some substance, been working on the rangefinder.  A friend of mine has a 3D printer, so I modeled up a stalk (based on the measurements from the WOF template) and he printed it for me:

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/3dprintedstalk.jpg)

It's really just a test piece.  It's two halves with a channel up the middle.  A servo extension wire fits in it, which I'll be using to run the NeoPixel Jewel in the RF proper.

After confirming that it works well I made a few tweaks to the design and then modeled the RF end piece and its cover to fit on the stalk and to hold the Jewel.  I can share the files if anyone wants, not sure what filetype to save them in, though (they're made in SolidWorks '15 Student Edition).
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Apr 14, 2016, 07:48 PM
The weather was very nice today, perfect for sitting outside and doing some helmet sanding.

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/sandycheeks.jpg)

After some bits of Apoxie Sculpt with some sharpie lines, I think one more bout of detailed sanding should nail down the cheek shape.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Apr 14, 2016, 07:59 PM
Looking good Vod. You're nearly there!
Title: Re: Bfa's WOF template build attempt
Post by: Bjourk on Apr 15, 2016, 01:09 AM
Love the wooden ears, looking forward to seeing your rangefinder complete!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 09, 2016, 01:58 PM
(http://i296.photobucket.com/albums/mm164/Bfahome/earcapstart.jpg)

Started attaching the ear caps.  The part over the RF pivot will be held on with magnets so it and the RF can be removed.  I also attached a little thing to the forehead because I though it'd look cool.  A few more touch-ups and it's time for primer, I think.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on May 09, 2016, 02:23 PM
The forehead thing does look pretty cool.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 11, 2016, 04:33 PM
It's prime time.

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/primetime.jpg)
Title: Re: Bfa's WOF template build attempt
Post by: Mavik on May 11, 2016, 04:41 PM
Always exciting
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 15, 2016, 10:01 PM
Took a short break from the helmet to graduate.

Decided to represent.

(http://i296.photobucket.com/albums/mm164/Bfahome/P05-02-16_20.58.jpg)

In actual news, got another rangefinder print from my buddy.  New stalk and the two pieces that form the end.

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/anotherrangefinder.jpg)

Interesting fact: the Adafruit NeoPixel Jewel fits almost perfectly into the lids of those little tubes that epoxy putty comes in.  I designed the inner piece of the RF model to have a circular hole that the lid can press-fit into.  Ta-da, fun and unique rangefinder "display" that can light up in fun and unique ways!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Jul 16, 2016, 06:24 PM
Been tidying up the helmet on and off for a while, making sure I can attach the right ear cap in a way that makes sense but still be removable to get to the rangefinder attachment.  Originally I thought magnets would be good to attach it but now I'm leaning towards short bolts that I can thread nuts onto from the inside of the helmet, provided there's room for my head of course.

Also been working on getting rid of artifacts of the build process, such as the bottom rim being rather weak and peeling from insufficient resin.  I added an extra layer of chipboard to try and solidify things a bit and resined that part again:

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/specificrim.jpg)

This should provide a better base for things like Bondo, Apoxie Sculpt, or epoxy putty to make the rim more solid.

Also, yes, that's a giant slot cut into the left side of the helmet.  I figure due to my lack of keyslots in the back I can have the ventilation system pull air through the slot down the middle of the left ear cap, because it's not really doing anything otherwise.  Two of the cooling pad fans stacked on top of each other covers pretty much the entire slot, and I think it'd be pretty cool to see the blue light coming from the inside.  Have to decide if I'm going to try and fit the third fan on the right side somehow and how that would interact with the ear cap, and whether it would be blowing inward to get ventilation from both sides or blowing outward to get a left-to-right airflow.
Title: Re: Bfa's WOF template build attempt
Post by: Jacyn Snow on Jul 26, 2016, 03:49 PM
looks good vode i like the greeblies you put on the front of the bucket looks cool
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Jul 31, 2016, 07:12 PM
Got a can of metallic silver as a base, decided to give the helmet a coat.

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/helmetsilvery.jpg)

Debating on how well to sand it because any silver visible will be from weathering and "damage" (explosive in origin) so I don't want it to look too perfect.
Title: Re: Bfa's WOF template build attempt
Post by: jango mando on Jul 31, 2016, 09:48 PM
looking awesome cant wait to see the final finished helmet

Also if you want arduino code for the servo rang finder just PM me as i used a custom arduino board to power and work the servo but it will work with a uno but im getting a nano for my helmet as its smaller but if you have another Adafruit Trinket that will work too for the servo.my sketch is a one button press the RF moves down for about 10 seconds or you can change how long then it auto raises the RF. 



Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Aug 22, 2016, 06:37 PM
Got the right ear cap functionally attachable.  A short bit of a dowel and some Buckycubes means it's removable but unlikely to come loose on its own.

(http://i296.photobucket.com/albums/mm164/Bfahome/earcapearcap.jpg)

Now I should be able to attach the servo on the inside, hopefully with the hole being large enough to allow the wire from the stalk to move along the arc.  But this means I can remove the rangefinder for storage or transport or whatever.  Just pop off the cap, unscrew it from the servo, and unplug the wire.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Mar 14, 2017, 12:54 AM
Sure has been a while.

I've been thinking about cutting the cheeks out of my bucket and re-doing them.

(http://i296.photobucket.com/albums/mm164/Bfahome/feelingcheeky.jpg)

They don't have any real "edges" to them and the surfaces just sort of blend together.  I think this was an issue with the fact that I made the mandible arches out of cardstock rather than chipboard.  Didn't make for a very sturdy shape.  I think I could make much more well-defined lines if I tried again.  Of course, this comes with the risk of losing some structural support and ending up with a warped helmet.

I dunno.  Anyone have any thoughts on it?
Title: Re: Bfa's WOF template build attempt
Post by: Bare Col'Mera on Mar 30, 2017, 10:16 PM
If you don't want to cut out the cheeks and start over, you could just use bondo to build the edge up and use some small files to cut the interior corner.  It'll be a lot less trouble than trying to start over.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Mar 31, 2017, 01:49 PM
Helmet build in my signature is all cardstock. The edge like Bare Col'Mera said can be built up with some work. I'd suggest layering some rondo with a chip brush as it should self level a bit. Don't go crazy or you'll end up with a super heavy bucket.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Apr 16, 2017, 05:00 PM
I've decided to split the difference and cut out the flat parts of the cheeks and replacing them (rather than the entire cheek+mandible portion).  I'm thinking that'd give me some good room to maneuver so I can sand down a nice sharp edge, then replace the flat parts with some small pieces of sintra.  Will be doing that once my Dremel battery is charged, because I always forget to do that.

e:
Carnage!

(http://i296.photobucket.com/albums/mm164/Bfahome/Mando/cheekless.jpg)

Initial cuts made.  Lines are where I'll cutting/sanding up to.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Apr 30, 2019, 07:13 PM
We go again.

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

Want to get a fresh start now that I have new tools and resources available to me.

Also Helmet Attempts 1 and 2 are in Maine and I'm not anymore, so that's bothersome.

So it's time for Helmet Attempt 3.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 02, 2019, 08:31 PM
:)

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

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

Current plan is no rangefinder, but I'm hoping to have the earcaps do something fun.
Title: Following!
Post by: RIGHTEYEBLACK on May 04, 2019, 08:52 AM
Wow.  loving this and enjoying seeing the out of the box thinking!  Just in the planning stages for mine, so I have a long road ahead of me.

Following just to watch!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 08, 2019, 04:33 PM
One of the new tools I have at my disposal is a laser cutter, and I decided to make use of it to create plywood base and cheek plates, since those are both pieces I want to be as flat and rigid as possible.

(https://i.imgur.com/zNB5y0u.jpg)
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 20, 2019, 03:18 PM
Plywood was a good idea!  I only glued the little bit at the front so far to get the alignment; since this is working so well I'm going to hold off on gluing the rest of it until I can get the top part (the dome base) cut out of another sheet of plywood to make sure the shape is consistent.

(https://i.imgur.com/i9u1Od0.jpg)

Also pictured is the mini helmet I started making a while ago for kicks.  Kinda want to finish that one up too. :P
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 24, 2019, 11:19 PM
Got to cut out the dome base ring today, so I finally have the shape glued!  The wood makes it nice and solid, and also means this time there won't be a lot of material to cut away after I've hardened it.

(https://i.imgur.com/dF94oOO.jpg)

It even fits! :P

(https://i.imgur.com/d7ppqhF.jpg)

Next up I think I'll trim the excess material around the bottom so it's flush with the wood, just to try and get a really nice edge to it.  That part turned out a bit sloppy during my last attempt.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on May 25, 2019, 04:20 AM
Freaking right on! Laser cutters!!! Looks super clean so far!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Jun 08, 2019, 08:46 PM
So I've cleaned up the edges around the top and bottom, just so the dome will fit nicely and the bottom looks nice and flush.
(https://i.imgur.com/QnGRxks.jpg)
(https://i.imgur.com/JDTSl7W.jpg)

As shown before I'd already made the face layer but I'm waiting to attach it.  Can't decide which order I'll be attaching the face and dome so I'm leaving it off for now.
(https://i.imgur.com/P0EJUfm.jpg)

Speaking of the dome:
(https://i.imgur.com/VJKPV3K.jpg)

The latest thing I did was cut this out, gonna see if I can make a decent dome.  Also probably gonna look around at thrift shops and see if I can find a helmet so I'd have that option too.  Weird how the board that I cut the dome rim out of is the perfect shape for what the dome is going to be! :P
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Jun 23, 2019, 11:36 PM
Helmet dome is my least favorite part of the helmet.  So many little bits and so finicky.  Ended up getting it all together but it's very lumpy and will need a lot of love in the sealing/bondoing phase to make it look okay.

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

I did, however, get a chance to go home for a day recently and that means I could pick up some supplies that I left there, including my armor, flight suit, weapons, other various decorative bits, and these bad boys:

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

Hoping the skate helmet can act as a decent backup if the scratch dome doesn't cut it.  The other helmet is still an abandoned project but I hope it can give me a good reference point for what to do and what not to do.  At the very least it's good for decoration.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Jul 03, 2019, 09:09 PM
So I'm starting to commit a bit here.  But I'm not sure how I want to proceed with the cheeks.  I want to have them be a bit different than the standard Jango/Boba, so I mocked up this design that fits within the template I'd already made.  (By the way I've now attached the outer face "plate" to the helmet base, that's what I meant when I said "commit".)

(https://i.imgur.com/QnW09lg.jpg)
(https://i.imgur.com/Sv3wBjK.jpg)

It's mildly reminiscent of Sabine's helmet, but it seems like it has a lot more "dead space" to it.  Does it look alright as-is, or is there something I could do to liven it up a bit?

Granted, the final plan is to have this thing lit up like a christmas tree so it may be good to have some areas that aren't saturated in details.
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Jul 14, 2019, 11:54 PM
Well decided to go standard.  That's what I made the wood rim on the base for so may as well fit it to that.  Still can't make clean-looking cheeks to save my life but hopefully I can add some battle damage and weathering that'll at least disguise those crimes, if not outright hide them.

(https://i.imgur.com/BRi7yw4.jpg)

One other thing is that I have the skate helmet to make the dome out of, so I'm thinking I may as well use that.  The issue is it's just slightly smaller and differently shaped than the wood ring I used around the top, so if I want to use the helmet I may have to rip out the ring.  Does it seem like it's worth it to do that?  Saves a lot of dome-making time and gives my head a tiny bit more room but also has potential to mess up the shape.  You can see the weird gap between brow ridge and dome the discrepancy makes in the pic below.

(https://i.imgur.com/vwDthOB.jpg)
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 15, 2019, 10:01 PM
so I still hate doing the cheeks

So I'm going to do something completely different to try and make them.

Enter vacuum forming. (https://twitter.com/Bfahome/status/1169639206051897344)

I've been working on a vacuum forming box for the makerspace I volunteer at, inspired by the little bit I did for Spirit (https://mandalorianmercs.org/forum/index.php?topic=172976.msg2022530).  Once I finish the box I think one of the first things I'm going to use it for is to vacuum form the cheeks for my helmet.

I started on the bucks today.  I did a lot of templating with a bunch of thin cardboard I got from work today, so I ripped the existing cheeks out of the bucket to make room and allow me to match the patterns to the helmet as best as I could.

(https://i.imgur.com/j3aaYGh.jpg)

I used the wood pieces to make sure the flat bits stay flat.  I have the general shape down and lightly reinforced.  At some point I'll hit this with resin to make it rigid, and then fill it out somehow, maybe with some bondo or something.  Need to be able to shape it and sand it down to get a nice crisp edge.  That's the whole point of this; I figure it'll be miles easier to get a crisp edge on a convex shape than a concave one.

(https://i.imgur.com/vpXwQ2Z.jpg)

There's both cheek bucks in their initial form.  I have what's essentially the hole that was cut out of the helmet, the gap in the bottom plane between the outer circumference and the cheek panel, the cheek panel itself, and some support bits.  All that space inside is hopefully going to be filled out.

We'll see how it goes!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on Sep 24, 2019, 04:19 PM
Since I've focused all my attention on trying to get Spirit done by Halloween, the vacuum forming box has been put on hold, so I decided to also see if I could template a more forgiving cheek shape vaguely inspired by The Mandalorian.

(https://i.imgur.com/eh4oKPe.jpg)

If I make these out of sintra or styrene after hardening the helmet then it'll save a lot of issues trying to get the lines to look nice.  I can still have the vacuum former as a backup if this doesn't work.
Title: Re: Bfa's WOF template build attempt
Post by: Bowfanny on Sep 27, 2019, 03:30 AM
Looking good!
Title: Re: Bfa's WOF template build attempt
Post by: Bfahome on May 29, 2020, 08:05 PM
haha it's been over a year since I started this version, I am so good at being motivated

anyway I actually finished the vacuum forming box (or at least finished it enough to hopefully be functional) but then the pandemic hit so I haven't had a chance to test it or do anything with it, but hopefully at some point I'll be able to get going on it.  In anticipation of that I threw some resin on the cheek/mandible bucks (resurrected from a rather crushed state in my packed closet) and should be able to build those up decently well.  Also epoxied the skate helmet dome onto the base.  Not sure what else to work on at the moment, since most of the next steps are going to require tools at the makerspace. :(  Maybe I'll finish up my blaster next.