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 Darklighter's Helmet WIP (PIC HEAVY)

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Karl Dha'Werda


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Darklighter's Helmet WIP (PIC HEAVY)
« on: Jul 25, 2015, 12:09 PM »
Hi y’all, I recently joined and started building my Mandalorian armour back in March of this year.  A friend at my church told me about how he was building his armour to join up here as well.  I’ve been into Star Wars since 3rd grade, around 1994 and my favorite character was Boba Fett.  Then in 2002 Star Wars II: Attack of the Clones came out.  Halloween was coming up and I wanted to be Jango Fett and my little brother wanted to be Boba.  Here is a picture of my first Mandalorian outfit:

Some of the images are not working and will be only the link:


I am currently in the Oyu’baat Clan out of Bismarck, North Dakota recently moving here at the beginning of the year after I finished college.  I look forward to attending events here after my suit is built.  This forum topic was started to keep track of what I’ve done so far and to get suggestions from y’all before I complete my application to become an official member.

I like to draw things, one of the reason I went into construction management as a major.  Below is my first schematic of how I wanted my armour and helmet to look (Hunter Green and Hunter Orange):


My first prototype of my helmet was a whole lot better than my Halloween costume years before.  This one I could see out of and not look through tiny holes poked in the cardboard.  The problem with this one was making it inside, boy does bondo smell.  I took it outside and it didn’t dry properly (probably had something to do with the -19 degree Bismarck winter).


My second prototype of my helmet came out child size and I tried plaster instead of bondo, didn’t work very well either.  Prototypes 3 and 4 I tried making with Sintra 2mm.  Tried is the key word because it is near impossible to get a perfect dome with that stuff.


Then one Saturday I sat down and attempted Prototype 5 of my helmet; following the templates almost exactly.  It had the right shape to it, but the dome seemed a little medieval looking.


That Saturday happened to be warm, which was weird but it worked to my advantage and the bondo I applied was able to set properly.  The image below shows prototypes 5, 1, and 2 (left to right).  I also got a garage at my apartment complex which helped keep the smell out of the house.  My wife appreciated it.  Also seen below is my 5th helmet and best fitting helmet yet.  Bondo on the inside and outside for a more solid helmet. Still needed a lot of work to get it down to the perfect shape.



My theory to show wear is to have my helmet or armour have a primed coat of metallic/chrome under the the coats of paint.  This way it appears to be a metal helmet.


Continued in next post (or not, combined posts into one with the modify button):

I then did mock ups of my helmet with Photoshop to try out the color scheme while waiting for the paint to dry on the real things and for the dark green shield/transparent visor package to get here.  Then when the visor came, I stuck it in the helmet to see what it looked like and it looked pretty good.  Similar to the mockup in Photoshop I used that Mandomaker today and made this concept of my helmet:


Later after a sale on May the 4th I got a Rubies 2-piece helmet with a more perfect dome.  My first priority was to get bondo on it to hide the seams and add texture like my schematics above show.  I generously used bondo to cover the entire helmet and what do you know the stuff sets a whole lot better when it is warm outside.



I then sanded/wire brushed the bondo down to the bare “metal” coat that I spray painted on (metallic black color).  After getting the initial coat of green paint on the helmet I toyed with the idea of using a grill in front of my visor, but abandoned it when I still had to figure out how to attach the visor.


I got the color schemes on the helmet and compared it with #5 prototype.  As you can see I thought #5 was good, but as you can see #6 is way better.  I also added wear and some grime from one of my cars into the back of the helmet.



I ended up using zip ties to hold the visor in place and made sure they were colored the same as the hunter orange accents around the visor (I’ll have to figure something out to hold it in there later).



Yesterday I had to repaint the bucket/helmet because the hunter orange I was using from Wal-Mart was discontinued and my new metal armour I'm working on would be in a different color.  The new hunter orange came from Lowe's.

« Last Edit: Jun 24, 2016, 10:33 PM by Karl Dha'Werda » Logged
Fair warning I like to take pictures and I've written a novel, so be prepared for both.
Karl Dha'Werda Facebook
Oyu'baat Clan
OM Troops: 54
Mandalorian WIP
Late Crusader 1330b
B.E.A.R.D.S#137|Mando Rider#038|ALUMINATI#036 FMM|MLCS#026|Oribru Akaata#54|MVS#100

Bowfanny


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  • When in doubt, be kind.
  • Awards Order of the Ori'Ramikad Celebration Chicago Award for 25 official invasions. 11+ Invasion Report Appearances Award for 10 official invasions.
Re: Darklighter's Helmet WIP
« Reply #1 on: Jul 27, 2015, 09:29 AM »
Oya Vod,
Couple of things here, multiple posts in a row is against forum rules, we all do it on occasion but we all get the proverbial hand slapping and reminder to not do it. I really like your enthusiasm for wanting to make your helmets and your multiple tries have given you great improvements along the way; however, one thing I notice is what we call icing the bondo which is basically putting too much on at one time. Smaller amounts get better results faster and they smooth out quite a bit better. Your J2P is a very good start but will likely need additional sanding to bring it to a smoother texture and I am sorry to say that the zip ties are not likely to fly for aesthetic purposes. But the great thing is everything is easily fixable but will take a little time. When I install my visors I use hot glue for quick installs but when I want to do my next one where I'll be making it remove-able I'll install Chicago screws inside the helmet itself and punch holes in the visor to fit over the posts. You're off to a fantastic start and if you need any help or encouragement please feel free to contact me and post here as I'll gladly keep an eye out for your updates and progress. Oya Vod!

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Karl Dha'Werda


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Re: Darklighter's Helmet WIP
« Reply #2 on: Jul 27, 2015, 02:09 PM »
Thanks Bowfanny.  I'm currently working with my CRL Compliance clan member.  I'm now looking into a resin helmet; a little more expensive but will be worth it in the long run.  I'll update this WIP when I figure everything out.

I'll keep it to one post from now on.  My first couple of WIPs were very long and I thought I would break them up by posts.

My wife says I've got to get a budget together before I go out buying bits and pieces.  The old helmet you see above (bondo icing) will be used by my wife for Halloween after she gets a color scheme together and will be more for fun (where zip ties won't matter) then trying to become official.

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Fair warning I like to take pictures and I've written a novel, so be prepared for both.
Karl Dha'Werda Facebook
Oyu'baat Clan
OM Troops: 54
Mandalorian WIP
Late Crusader 1330b
B.E.A.R.D.S#137|Mando Rider#038|ALUMINATI#036 FMM|MLCS#026|Oribru Akaata#54|MVS#100

Bowfanny


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  • 8791
  • When in doubt, be kind.
  • Awards Order of the Ori'Ramikad Celebration Chicago Award for 25 official invasions. 11+ Invasion Report Appearances Award for 10 official invasions.
Re: Darklighter's Helmet WIP
« Reply #3 on: Jul 27, 2015, 02:40 PM »
If you want or need help please remember I'm here. ;D

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Karl Dha'Werda


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Re: Darklighter's Helmet WIP
« Reply #4 on: Oct 04, 2015, 09:40 PM »
Bump and update on my WIP since my last post.  Rather than post again I will just post the links to my blog where I keep track of my WIPs.


Helmet: https://mandalorianarmour.wordpress.com/2015/07/24/helmet/


Helmet2: https://mandalorianarmour.wordpress.com/2015/10/04/helmet2/


Helmet3: https://mandalorianarmour.wordpress.com/2015/10/05/helmet3/


« Last Edit: Oct 30, 2016, 04:33 PM by Karl Dha'Werda » Logged
Fair warning I like to take pictures and I've written a novel, so be prepared for both.
Karl Dha'Werda Facebook
Oyu'baat Clan
OM Troops: 54
Mandalorian WIP
Late Crusader 1330b
B.E.A.R.D.S#137|Mando Rider#038|ALUMINATI#036 FMM|MLCS#026|Oribru Akaata#54|MVS#100

Karl Dha'Werda


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  • MMCC Karl & Rex Dha'Werda and TDE#388
  • Awards Award for 50 official invasions. 11+ Invasion Report Appearances Award for 10 official invasions. Award for 25 official invasions. Repeat appearance in the invasion reports
Re: Darklighter's Helmet WIP
« Reply #5 on: Jun 24, 2016, 10:16 PM »
Haven't posted in quite awhile.

If you want or need help please remember I'm here. ;D

And this ^^ is why I PM'ed you Helmet Master; about the Late Crusader Helmet.

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Fair warning I like to take pictures and I've written a novel, so be prepared for both.
Karl Dha'Werda Facebook
Oyu'baat Clan
OM Troops: 54
Mandalorian WIP
Late Crusader 1330b
B.E.A.R.D.S#137|Mando Rider#038|ALUMINATI#036 FMM|MLCS#026|Oribru Akaata#54|MVS#100

Bowfanny


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  • 8791
  • When in doubt, be kind.
  • Awards Order of the Ori'Ramikad Celebration Chicago Award for 25 official invasions. 11+ Invasion Report Appearances Award for 10 official invasions.
Re: Darklighter's Helmet WIP
« Reply #6 on: Jun 25, 2016, 12:14 AM »
Haven't posted in quite awhile.

And this ^^ is why I PM'ed you Helmet Master; about the Late Crusader Helmet.
I am here for my Vode.

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Karl Dha'Werda


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Re: Darklighter's Helmet WIP (PIC HEAVY)
« Reply #7 on: Dec 29, 2019, 12:04 PM »
Looks like I never updated my work in progress to showcase the helmet I have been using for the last 4 years with my kit.  Also known as Helmet 3.

10/5/2015:

My last post left off with a Jango Fett 2-piece plastic helmet modified and visor held in with zip-ties.  I’ve since ordered a new helmet from Head Shot Props.  It is the Generi-Fett Left is a 1:1 scale Fett style helmet without a range finder.  The big selling point for me was not having the range finder like my schematic drawings back in March.



The helmet came the day after my birthday which was cool.  I got a dremel tool for my birthday so it worked out perfectly as I would need to cut out the visor and the mold excess at the bottom.



I cut out the visor and then removed the excess from the mold off the bottom and then I primed the helmet a few times.  I also added battle scars to the helmet at this stage with distinct worn patterns across the front.



I then put a couple coats of a metallic spray paint (aluminum in color).



I let the metallic coat dry overnight and grabbed prototype #1 to compare to my final helmet.



Adding toothpaste for weathering and “to smell minty fresh” -Tiric Keel

I got it on the edges of where the hunter orange & hunter green meet and deep in the battle scars.



Hunter green base coat; I’ll add the hunter orange accents next.



Taping up all the hunter green paint after it dried a few hours to added the accents.



Hunter Orange accents.



Toothpaste removed and weathering applied to the helmet





These (below) are comparisons to my helmets.  First one is my prototype #5 made out of cardboard and bondo next to my final helmet.  The second photo shows my previous 2-pc Jango helmet #6 next to my final helmet.  Quite a difference and very noticeably better looking.  Head Shot Props does a really good job with their resin buckets.



Visor held in with velcro for now.  It makes for a easy quick removal with touching up the paint.  I will eventually use a hot glue to set the visor in better.  Also seen above with helmet #6 and my helmet final is the visor colors are described as the same online ‘dark green.’  This new one is noticeably green when looking around through the visor, but hey at least you can’t see my face.  I also got some helmet pads from ebay, which work good for padding inside my helmet.



I recently got out my paint and added rust color metallic paint to the worn spots.  I’ve also added lighter green specks to the dome of the helmet in the battle scar and weathering areas.  Same with the orange, to give it a more realistic feel (suggestion from Sentinel).  This helmet now looks like it has been used thoroughly and matches the same amount of weathering as my schematic rendering.  The armour is not quite to this level yet.



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« Last Edit: Dec 30, 2019, 01:02 PM by Karl Dha'Werda » Logged
Fair warning I like to take pictures and I've written a novel, so be prepared for both.
Karl Dha'Werda Facebook
Oyu'baat Clan
OM Troops: 54
Mandalorian WIP
Late Crusader 1330b
B.E.A.R.D.S#137|Mando Rider#038|ALUMINATI#036 FMM|MLCS#026|Oribru Akaata#54|MVS#100

Karl Dha'Werda


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  • 1115
  • MMCC Karl & Rex Dha'Werda and TDE#388
  • Awards Award for 50 official invasions. 11+ Invasion Report Appearances Award for 10 official invasions. Award for 25 official invasions. Repeat appearance in the invasion reports
Re: Darklighter's Helmet WIP (PIC HEAVY)
« Reply #8 on: Dec 30, 2019, 01:07 PM »

12/28/19  Helmet 4



A little over 4 years later it is time I upgrade my helmet.  This helmet is entirely metal and comes from Acacin Armouries here on the forums.  My previous helmet (see WIP above), known as Helmet 3 was starting to warp around the visor area.  This might have happened because I replaced my visor.  The velcro held up for 3+ years, I used hot glue to put in the new visor and it was less than satisfactory.

I first learned about Dresdon when my clan’s Alor’ad mentioned a guy up in Canada that made custom metal armour, helmets, gauntlets, and pretty much anything he wants to make out of metal.  I joined a society on the Mandalorian Mercs forums called Aluminati.  Aluminati was setup to showcase those Mandalorian that have the majority if not all of their armour metal.  My number is #036.  If a member has full metal armour they’ll have FMM attached to their number.  Stands for Full Metal Mando in this metal armour society.

#000 – Dresdon Acacin – FMM

#036 – Karl Dha’Werda

The majority of my armour falls into this society and I requested membership for this society on April 3rd, 2016.

Light Modern Armour (All metal is 16 gauge stainless steel sheet metal, with 20 gauge shoulder bells and backplate).

METAL: Back plate (mostly covered by jetpack), chest plates, center diamond plate, abdominal plate, collar plate, shoulder bells, codpiece, kidney plate, blaster (DL-44), carbine rifle (EE-3), and gauntlets are all metal.

ABS: Knees (I had a pair made by Mandalore the Uniter in October, but they ended up being too small for me.  I have another commission for a larger set to be made mid-January 2020).

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July 15th, 2019: Dresdon contacted me about someone dropping out of his helmet run and if I wanted to drop in the slot.  There was no if for me, I jumped at the opportunity.  Figured out what style helmet I wanted and sent PayPal to him for the full amount.  The style helmet I went with was basic, standard earcaps, diamond rear plate with death star vent pattern, and a slight peak in the front of the visor.  The helmet will be replacing my current fiber-resin cast helmet I’ve been using since I became official in November 2015 (see below).  The years have not been great on it, and as mentioned above it is starting to warp from a few of the really warm troops over the years.



On September 4th I got to see my helmet for the first time.  I was super stoked to see it assembled.



The next update was on October 13th, 2019.  Lots of filling and sanding.



October 21st, 2019 I got another update.  More filling and sanding.



October 23rd, 2019 Update: “With the exception of a couple divots like in the earcap tops yoyr buckets good to go for final primer- this stuff is easily hidden with blackwash. Are you ok with this?” With the amount of weathering I needed to do to match the rest of my kit I was okay with Dresdon’s concern areas (see below).



On December 12th, 2019 I was notified that my helmet had been primed and was ready to be shipped.



December 24th (Christmas Eve), 2019 my package arrived.  It was very well wrapped with bubble wrap and secure in the box when I opened it.



Super excited to start painting my new helmet.



I did a test fit on myself and threw the full mirrored visor in to just see the color.  When fully painted and weathered I will cut the visor to size and insert in front of the lower bracket.  I also got some stickers.



I started by taping and prepping for the base green coats.  In the middle of winter, so I painted in my garage.



Once multiple coats had been applied and dried I brought it inside.  I removed the painters tape and set it to dry overnight.



The next morning I taped up everything except where the orange accent color would be. Then I applied the orange paint.



Later that night after the orange had set and dried in the house, I removed the painters tape.



I then prepped it for the remaining black paint areas.  I applied painters tape every except where the black would be.  Then sprayed on a few black coats of paint.



The next morning my helmet was completely painted and dried.  Ready for weathering.  The colors below are in different lighting locations.  They are the same in both.



I did a side-by-side comparison of old vs. new to see the difference and what I needed to match.  The old helmet is more weathered and has a slightly darker paint than my plates on my kit, but mostly because it has been around longer.



I then started the weathering process by first using a flathead screwdriver to chip away any drip and over spray areas.  Then I used an exacto knife to peel away more paint to match a similar weathering pattern as my old helmet.  On the back I used a metal etching tool to sketch in a mythosaur to the back of my helmet dome.



I then went into the garage and started weathering with a butane torch, which made the orange paint turn yellow.  I then made a blaster mark on the right rear of the dome, similar location to where there was a mark on my old helmet.  I used lighter green on all the hunter green areas to rub into showing metal areas to give more of a weathered look like the orange to yellow.



After the lighter green was applied I used acetone to clear the whole helmet and to show additional weathering.  I then weathering my helmet with rocks and dirt.




After I obtained the weathering with a high heat effect on the helmet.  I also started carbon scoring the helmet with my butane torch.  Making the orange around the visor match my old helmet.




The weathering on my helmet now matches the rest of my kit.  Below are comparisons to one of my shoulder bells, chest plates, and my back plate with my jetpack.



I then did another side-by-side comparison of my old helmet vs. my new one after weathering it.



Old vs. new with green visor in place.  This mirrored green visor from Kalevala Visors.



Next I had to reach out to Dresdon to make sure I put the HUD lights in the right place.  I wasn’t sure if it was supposed to be on the inside or outside of the visor.



Dresdon confirmed that it will need to be on the outside, so it shines down the front of my visor.  I glued the lights in place and then I wrapped the wires in electrical tubes to prevent damage during troops.  I used velcro to attach the battery pack.



After a test fit of the visor using a paper template first I cut the visor to fit in better.  I also added more padding, trying it on with every pad to make sure it still fit correctly.



HUDs are set.  A Heads-up display, or HUD, was a view screen projection that functioned as a form of visual aid. HUD units were fitted into the helmet.



My HUDs were in place and my helmet is complete.  The light on looks really cool, but off looks great too with the mirrored green visor.  It is the same color as Clone Commander Gree’s lenses.



My Vizsla pup, Copper approves.


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Fair warning I like to take pictures and I've written a novel, so be prepared for both.
Karl Dha'Werda Facebook
Oyu'baat Clan
OM Troops: 54
Mandalorian WIP
Late Crusader 1330b
B.E.A.R.D.S#137|Mando Rider#038|ALUMINATI#036 FMM|MLCS#026|Oribru Akaata#54|MVS#100

Bowfanny


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  • 8791
  • When in doubt, be kind.
  • Awards Order of the Ori'Ramikad Celebration Chicago Award for 25 official invasions. 11+ Invasion Report Appearances Award for 10 official invasions.
Re: Darklighter's Helmet WIP (PIC HEAVY)
« Reply #9 on: Dec 30, 2019, 09:30 PM »
Started scrolling through this page on the thread and immediately had flashbacks to four years ago Vod! Glad to see you still at it and now with a sexy new chrome dome! Fabulous!
Looking amazing!

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Karl Dha'Werda


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  • MMCC Karl & Rex Dha'Werda and TDE#388
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Re: Darklighter's Helmet WIP (PIC HEAVY)
« Reply #10 on: Dec 31, 2019, 07:58 AM »
Looking amazing!

Thanks Bowfanny!  It has been a great ride learning each day and helping make the world a better place with more Star Wars.  ;)

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Fair warning I like to take pictures and I've written a novel, so be prepared for both.
Karl Dha'Werda Facebook
Oyu'baat Clan
OM Troops: 54
Mandalorian WIP
Late Crusader 1330b
B.E.A.R.D.S#137|Mando Rider#038|ALUMINATI#036 FMM|MLCS#026|Oribru Akaata#54|MVS#100
 


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