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[Catra Veshok]

Su'cuy! I think I'm far enough along in trying to figure out how to put together a bucket to start sharing progress. I'm going with the bike helmet + actual bucket approach. The biggest issue I've run into so far is sizing. I'm kind of small. Even a 5-7 year-old bike helmet looks too big sideways. I'll have to cut it down to size. I started with an 8+ helmet, and that was way too big. But I learned some things while was working with it, so you'll see pictures with that too. Also, if you're interested in my concept thread, here's a link (let's see if it works): http://mandalorianmercs.org/forum/index.php?topic=204700.msg2238509#msg2238509
Be prepared for detailed posts because a) that's how my brain works and b) maybe it'll be helpful for somebody who's also learning how to do this.

Here goes . . .

I'd made this paper pattern awhile ago and tried it out on my 8+ size helmet. I was worried it was all too wide, but as someone pointed out on my concept thread, I just need to make sure it's no wider than half of shoulder width with armor.



I sanded down the helmet, inside and out. Maybe this was a waste of time, since I'm using a different helmet now. But I can always practice painting on it and use it as an actual bike helmet. I had a struggle tugging the foam layer out of the inside of the shell, until I realized the popping sounds weren't plastic cracking. It was glue unsticking from the plastic.
After sanding, I sprayed the helmet down to get off any excess. Then I let it hang out with my paint tests while it dried. After it dried, I noticed some spots that weren't sanded as well but were hard to see before with all the residue. So I sanded some more.







Later, I measured between the helmet's strap rivets for the center front of the helmet.





I decided I needed to add a piece to the front to give myself a little more surface area to work with when attaching the bottom part of the bucket. So I made a paper pattern for that. One very important thing I learned is that a curved 3D shape does not have a straight line when flattened, so I need to make patterns on the curve, not flat. Here's the process I did. (Some pictures I took after the fact, after realizing I wanted to log all the steps.)





I held the paper up to the light to line up the pencil line and then fold the center of it.



Measuring the height difference



Transferring that measurement to paper, then cutting, then lining up the centers, then overlapping











I traced out the pattern based on the overlap, then cut it out, then taped it to the helmet. If you look close, you'll notice that the flat pattern is slightly curved when flat, but is level when curved in a 3D shape.



I folded down the excess to more or less level it out all across, then trimmed off the excess.







Now attaching a pattern based on my old blue one and the Wizard of Flight Boba Fett Helmet pattern. http://mandalorianmercs.org/get-involved/costume-templates/



Ta daaaa. Not perfect, but it was a start.



Cutting the lower bucket pattern out of poster board, then adding half an inch in case I need more to work. Still debating whether I'll actually need that.




To be continued... with a new and smaller bike helmet.

[Catra Veshok]

Okay, here's the start of my work on the smaller helmet. It was the smallest I could find that had a hard plastic shell and a detachable foam layer. I was lucky I didn't have to carry a Barbie helmet out of the store. As it was, I got some odd looks. If asked, I was prepared to say, "It's for my niece..." or just tell the truth and say, "I'm making a Mando costume!"
"With a bright pink kid's helmet?"
"Yeah! I'm... painting it something else."
Don't get me wrong. If bright pink is your thing, that's great. I like the more earthy colors myself.

Anyway...

What do you think of these sample designs? No? Okay. I'll go with something else...



Still had to add some width to the pattern for this helmet. I cut it in half down the front, then cut it out again so the back would be all one solid piece.



Hello there. I taped the new pattern on the helmet, then added just the front part of the flimsi ... er .... regular paper pattern.



I was having struggles getting stuff to line up and look good. Then I realized I needed to do the same thing I'd done with making that little pattern to add onto the old helmet. I needed to make the faceplate pattern on a curve, not flat. So I made yet another new faceplate pattern, drawing it on a clean sheet of paper that was taped to the helmet so I could get the curve. Sadly, I didn't get pictures of that. I had to move the old pattern around with each section -- the eyes, the mandibles -- to fit with the curve. After that, I scaled down that little piece I'd made for the big helmet, then added it to the new faceplate pattern.





I took to using a headlamp so my own shadow wouldn't put a strain on my eyes while I was working.



Now it lines up nicely with the curve of the helmet.



Ta daaaa (again). Not perfectly centered, but we'll get to that. And I'll either have to trim the mandibles or bring back some of that extra half inch on the piece beneath them.



It's still too long sideways. So I marked how much I'll need to cut out to fit the original Boba Fett pattern better and just look better. Also, I'll have to figure out the sides of the faceplate.

[Rilal Birom]

Building your own helm?  Bold move!  Looks like it's shaping up well!  I'm a bit partial to the Night Owl style as I've chosen that style for my own build...so I may be biased, lol!  Can't wait to see it completed!

[BLINDGIANT]

I used the same pink bike helm for my helm.
I recently posted in the “helmet” forum.

I think one of the unexpected outcomes of a diy like we both went for…. Is that brow ridge ends up about 1/4 inch. Which some have told me is frowned upon. So I wanted to ask the community for opinions. I got1 response… but it was positive enough that I’m going to move forward.
If you need pointers… here is an important one.
When working the cuts together for you cheeks/fangs,… hold the prices and hot glue them into place placeing the hot glue on the outside (thick) once you have everything glued in, now use fiberglass resin (in small batches) with small 1.5 x 1.5 inch fiberglass cut pieces on the inside. Once that resin has dried, you can peel off the hot glue from the outside and fill the outside spaces with filler.

http://mandalorianmercs.org/forum/index.php?board=9.0

[Catra Veshok]

I used the same pink bike helm for my helm.
I recently posted in the “helmet” forum.

I think one of the unexpected outcomes of a diy like we both went for…. Is that brow ridge ends up about 1/4 inch. Which some have told me is frowned upon. So I wanted to ask the community for opinions. I got1 response… but it was positive enough that I’m going to move forward.
If you need pointers… here is an important one.
When working the cuts together for you cheeks/fangs,… hold the prices and hot glue them into place placeing the hot glue on the outside (thick) once you have everything glued in, now use fiberglass resin (in small batches) with small 1.5 x 1.5 inch fiberglass cut pieces on the inside. Once that resin has dried, you can peel off the hot glue from the outside and fill the outside spaces with filler.

http://mandalorianmercs.org/forum/index.php?board=9.0

Thanks for the heads up on the brow ridge. I'll keep that in mind as I finalize the patterns. Maybe I'll do  some kind of layered look, so it's 1/8 ", and then 1/8" instead of 1/4" all at once, if I'm making any sense. And thank you for the tip on gluing and fiberglass! Much appreciated! Do you also use the fiberglass resin on the outside for filler?

[Catra Veshok]

Building your own helm?  Bold move!  Looks like it's shaping up well!  I'm a bit partial to the Night Owl style as I've chosen that style for my own build...so I may be biased, lol!  Can't wait to see it completed!

Thanks! Yeah, the Night Owl style definitely has character

[Cattriss Wren]

Su'cuy Cat'ra. Great job so far!! I'm very impressed that you're making it yourself!! I am also following

[Catra Veshok]

Here's the latest progress.

I cut the helmet down to what I think is now the right size. First, I used an Xacto knife, scoring the surface, then cutting deeper and deeper until I could cut through easily. That took awhile, and it was just one side.



Then I went down to my buir's (my dad's) over the weekend. I spent some time on my helmet there. I used a hacksaw next. (I should just get one.) That was also taking awhile because of the awkward angles. So my dad brought over a jigsaw and had me hold the helmet steady while he finished cutting the helmet. Thanks, dad.



Then I sanded.



Then after I got home, I applied some fiberglass resin to put the two pieces together and prepare for filling the holes. I've been watching these helpful videos on helmet construction, and that's how I learned to do the bondo: https://youtu.be/W3TfUh_Y7z8

Honestly, bondoing made me kinda nervous because it's such a strong chemical. But I wore protective stuff and managed alright I think.

First, I poured measurements of in a cup and marked the levels so I'd be decently accurate with the resin/hardener ratio. I decided on a lighter colored cup so I could see the levels easier.





Helmet sanded, taped and ready.  The edges don't line up exactly along where I cut, so I left a tiny bit of space between so the bondo application can even it out some. I still might need to do some heavy sanding and trimming to smooth it all out.



I didn't take time for pictures while applying the bondo and fiberglass cloth because it hardens fast, and my hands were full. But the video I put a link to shows how it's done.

Here's the helmet next morning, after it rained and I found a pool of water in the bottom. I ejected that before taking a picture... though in Clan Krayt territory, what's still there might be considered a pool of water. Rain is rare and welcome here, especially this year. So I wasn't mad. Besides, the resin was already hard, and it seems to repel water. I'm waiting another day at least for it it finish curing completely. It's still slightly sticky to the touch, though hard. It seems to have strengthened the helmet, and the helmet is noticeably heavier. Next step will be putting either bondo resin or filler on top in the same places. The fiber fabric + resin on the inside of the helmet forms a base for that.

[Skub Dunkhus]

Here's the latest progress.

I cut the helmet down to what I think is now the right size. First, I used an Xacto knife, scoring the surface, then cutting deeper and deeper until I could cut through easily. That took awhile, and it was just one side.



Then I went down to my buir's (my dad's) over the weekend. I spent some time on my helmet there. I used a hacksaw next. (I should just get one.) That was also taking awhile because of the awkward angles. So my dad brought over a jigsaw and had me hold the helmet steady while he finished cutting the helmet. Thanks, dad.



Then I sanded.



Then after I got home, I applied some fiberglass resin to put the two pieces together and prepare for filling the holes. I've been watching these helpful videos on helmet construction, and that's how I learned to do the bondo: https://youtu.be/W3TfUh_Y7z8

Honestly, bondoing made me kinda nervous because it's such a strong chemical. But I wore protective stuff and managed alright I think.

First, I poured measurements of in a cup and marked the levels so I'd be decently accurate with the resin/hardener ratio. I decided on a lighter colored cup so I could see the levels easier.





Helmet sanded, taped and ready.  The edges don't line up exactly along where I cut, so I left a tiny bit of space between so the bondo application can even it out some. I still might need to do some heavy sanding and trimming to smooth it all out.



I didn't take time for pictures while applying the bondo and fiberglass cloth because it hardens fast, and my hands were full. But the video I put a link to shows how it's done.

Here's the helmet next morning, after it rained and I found a pool of water in the bottom. I ejected that before taking a picture... though in Clan Krayt territory, what's still there might be considered a pool of water. Rain is rare and welcome here, especially this year. So I wasn't mad. Besides, the resin was already hard, and it seems to repel water. I'm waiting another day at least for it it finish curing completely. It's still slightly sticky to the touch, though hard. It seems to have strengthened the helmet, and the helmet is noticeably heavier. Next step will be putting either bondo resin or filler on top in the same places. The fiber fabric + resin on the inside of the helmet forms a base for that.

Looking good! I haven't seen many attempts from scratch, this is impressive! Definitely interested in seeing how this turns out!

[Catra Veshok]

Well, it's been awhile. But I've been working at it! Adjusting the paper patterns to fit this modified bike helmet has been a struggle. I won't write all the details here, just post some pictures. I think I'm finally ready to cut out the plastic.

Cleaning up after first fiberglass bondo application:

[Catra Veshok]

Figuring out paper patters has been . . . not easy. You'll see I've tried to combine those WOF Boba Fett templates with something Night-Owlish. The real struggle has been getting the pieces to fit snug against the curve of the helmet without spreading out too much at the bottom and to stay horizontally level against the bike helmet. I woke up in the middle of the night a couple times with my brain trying to figure out a solution. I'm sure the WOF template works better if ALL the pieces you use are from the template. Using a bike helmet has meant a lot more adjustment than I anticipated. Maybe I'm being too much of a perfectionist. It happens.





Took a break to fix some spots the bondo slid away from and left unfilled while drying the first time.





More sanding for a nice smooth surface



Sanded the inside in case I need to glue in padding. Beautiful...



Setting up to draw a level horizontal line around the helmet





Decided to include the treble clef towel holder in the ensemble. (Get it?...)



Oops. Steady . . . steady . . .





See how much the paper sticks out away from the helmet?



Tried drawing a line around the helmet with a paper shell to make a pattern. This didn't work at all.



Redrew the line on the helmet for a better angle. And my studio is a disaster right now.   



More work with patterns. Just looking at these makes me feel tired.



















Tried making darts



Nah. Not gonna work.



Took another break to saw off some excess material on the helmet.



Compromise: Combining WOF with my own pattern





Hmmm....



Adding other pieces kinda makes it better.



Combining WOF Boba Fett with Night Owl









I think I'm onto something. When I do the real deal, I'll cut out along the eyes all the way. I just did those slits for now so I could sorta see while trying this on. Also, the pieces are taped on a little crookedly, but I'll see to that later.







I feel like it's still a little big, but when I do the cheeks, hopefully that'll bring it in so it's less wide. And I'll make sure my shoulder armor is wide enough to compensate. P.S. That's the top part of my flight suit. I'll start up a soft parts thread for what I've been doing with that... eventually.

Or actually today. Here's the link: https://mandalorianmercs.org/forum/index.php?topic=205883.0

[Vercopaanir]

Another scratch bucket builder! 

I highly recommend looking up the Bearded Mando's bucket tutorial/builds on YouTube.  He also has thread in the Helmets section but it's probably buried by now.  He has a ton of helpful tips and tricks to making a bucket from scratch. 

You also welcome to poke through my bucket build thread.  I attached several different tutorials that I used to help with mine into the build.  I also made notes on things that did or didn't work.  Might help you avoid some of the mistakes I made when I built my helmets.

It's highly rewarding to hand someone my helmet and say I built it.  Most just kinda give me this wide eye look when I turn it over to show them the 5 gallon bucket interior. 

Good luck with this! 

[Catra Veshok]

Thank you!  I'll take a look through your bucket build thread. I've been watching the Bearded Mando's videos, and they've been really helpful. Yeah, I figure it will be rewarding once it's all done. I'm learning a lot of skills and gathering tools that will hopefully come in handy later on, for future builds and other projects!

[Catra Veshok]

Okay, posting some more progress.

I learned how to use a jigsaw over the long weekend at my dad's. I did the simpler bottom piece, and I let him do the face. He insisted -- and proved -- that he's really good at precision with a jigsaw. I mean, I believed him. It's just that normally, I like to do stuff myself. But I'd cut that darn pattern out in so many variations so many times out of paper already, and I'm trying to get this done in time for an event, and an Xacto knife would take forever, so I let him do it and was very grateful for it.

And let me tell you, once we were done cutting those pieces, it was such a good feeling having them tangible in my hands and not just paper.









After getting back home, I drilled some holes, traced temporary lines along the face piece, and did some riveting. I don't remember exactly which order that was in, exactly, except that the riveting came after the drilling for sure. It was my first time using a rivet tool. Not the best job ever, but it's holding. I'm learning a lot of stuff these days!





Then I designed, cut, and glued on a decorative piece. I used 2-part epoxy, 1 minute set, so I had to work fast. It takes about an hour to cure.



While I waited for the epoxy to cure, I set about figuring out the cheekbone and earpiece patterns based on the WOF Boba Fett templates. I saved the paper patterns for things I'd already cut out, and I'm glad I did. I can use them as guides for other pieces. I've taken to writing the scaling percentages on pattern pieces so I can refer back to them on the PDF if needed. Each PDF is scaled differently -- at least on the reader I have -- so even though most of the helmet has been at 67.5% so far, the earpieces ended up being 195%.





Ta daaa. All cured. It feels all better.

Wait...



And here's where it became clear I'd made a mistake. When I was riveting -- yes, I used to be such an interesting person...
Okay. I'm full of puns tonight apparently. Sorry. Anyway...

WHEN I was riveting, I didn't stick to the plan with the front. I brought it down, thinking to make it more even across, even though I'd PLANNED for using the weird shapes as part of the decoration and sanding it over and everything. So now, the face piece didn't work anymore. It didn't sit flush like it was supposed to.

Enter Vader. "NOOOOooooo."
Okay, I guess it's not that drastic.





So after some stressing, here's the solution I came up with. Hopefully it'll work. I cut a V into the face, kind of mimicking the decoration I'd glued on earlier. Then I learned how to use a heat gun and molded the top rim of the face closer against the helmet. The V made that possible, or at least easier to do.





Then I retraced the face pattern in darker ink and stuck it on with E6000.

The poor helmet looks like it's being swarmed by fire creepers with all those clamps.

I've been listening to Star Wars audiobooks while working on this. Hence the fire creepers reference. Not a pleasant thing to think of.





I promise, helmet, I'll release you from the clamps tomorrow. (Late tomorrow.)
And while I wait for the E6000 to cure, and when I'm not working, I'll do more on the soft parts.

[Catra Veshok]

Time for another update. I'll separate it into a few posts because a lot has happened since the last.

As promised, I took off the clamps the next night, then set to work again in the morning.



At some point in the process, I learned that cutting the plastic is a lot easier when it's been heated somewhat. Thanks Vercopaanir! I got the idea from your thread.
I also found that after some scoring, I could bend it and the Xacto would slide through the rest nice and easy.



Ta daaa.
As you can see, one side is sticking out more than the other. I tried to heat form it to be even with the other, but it's still causing a little trouble. Next time I'll be more careful to line stuff up evenly before gluing.



It's most of a face! 
Checking to make sure the helmet is long enough. Yeah, I think it is.

Modifying the cheekbone pattern to fit with my design.



Starting to look like something!



Traced the patterns onto concave and convex curves and at angles that would make them easier to shape.







I had to painstakingly cut back some of the bike helmet because I glued the ACE bucket pieces a little higher than I'd meant to. I really need to stick with my own plans better. 

I attempted to epoxy the heat-shaped cheekbones on. That wasn't working for me at all. So I resorted to hot glue. I had worried that it would melt while I waited for the resin on the inside to dry. Hence the attempt with epoxy. But I needn't have worried, since I ended up doing the resin at night when it was cooler.







I cut off the excess length in the back, and I'll use that piece to reinforce the inside.



When heat forming the ACE bucket piece to sit flush against the helmet, I got a little carried away with the heat gun and melted a bit. That meant sanding down later.



Ta daaa



Well, I decided I didn't like how the top cheekbone pieces curved in toward the edge of the helmet, so I did more heat forming to get them to stick out later. It's a good thing I didn't do epoxy before that point. The hot glue melted where I needed to reshape, and then I could glue it back together. For some reason I don't have a picture from right after the reshaping. But you'll see later on.