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[Raestin Ke'Varek]

I'll second what the others have said, don't get discouraged.  It's definitely NOT a lost cause, and it's not too late to turn this into a masterpiece. 

As for the ridge, most scratch builds have the ridge (as well as most production helmets).  When you make one from scratch, generally you'll start with a dome (from scratch or premade), then you'll add the "inner layer" onto the bottom of the dome with a bit of overlap.  This gives you something to secure the dome to the bottom of the dome using screws or rivets.  After that's secure, you'll add the "outer" layer onto that.  So if you're using 3mm sintra, you'd have a 6mm ridge from the visor to the dome.  That's pretty thick, but it is what it is.   

I made a crude drawing with each of the layers, I hope this helps (and makes sense).  I really want this to work out for you!!

[vluvski]

I lost some momentum while getting ready for a Halloween party, but I'm back on it.  I'll be a little slow while I focus on the rest of my build for a party THIS WEEKEND, but I want to finish this out with an approvable helmet, eventually.


I didn't take mayn photos this phase because, well, it's tough to see the improvements in black plastic with my crappy lighting.  I added a band to create some stability for the dome to mask seam, but it still needs smoothing and shaping.  I also applied bondo to the two seams in the dome.

I took the advice to cut out the cheek and improve the lines/symmetry on the T, and while it looks a lot better, I didn't quite get it to where I wanted.  I can't decide if it's worth taking back out again this time.  I'm thinking no.  I did cut out ear pieces; the back piece will be similar but wider and taller-not cut yet; photo showing that is just an ear piece for the general gist.
[URL=http://s359.photobucket.com/user/vluvski/media/IMAG0851_zpssrerux9h.jpg.html][URL=http://s359.photobucket.com/user/vluvski/media/IMAG0856_zpsmt1jhfez.jpg.html]

[Kjeldo]

The scratch built buy'ce is a great undertaking!  Our Clan Alor'ad has a great tutorial that I'd like to share with you.  The components are quite reasonable and I've seen quite a few done in this manner.  Here's the link for your consideration...

http://mandalorianmercs.org/forum/index.php?topic=76655.0

Oya, Vod!

[Syko Voss]

Definitely - I think what made life easier for us was using the existing dome from a Skate Helmet - that gives you a solid base that you know will fit your head.
I'd recommend following up on Kjeldo's link and Raestin's WIP - both show excellent examples.

We've built two from scratch using skateboard helmets for domes...



Here's the link to our WIP that details how we did it, pretty much step-by-step: http://mandalorianmercs.org/forum/index.php?topic=93907.15

I will say that building a form out of cardboard makes all the difference when shaping...


And having a second pair of hands to help is a big bonus.  If you're having trouble forming the cheeks - have a look at Raestin's WIP - his method of breaking it down into smaller sections makes the process a lot more controllable.

But don't give up - you might have to backtrack and start afresh, but you'll be doing that with all the knowledge and skills you've built up so far.
Best of luck!

[vluvski]

I had to put things on hold for awhile, but I have made some pictured progress.  I think the overall helmet is beginning to take shape now. 

Frontal:

This photos shows what I feel are the two biggest challenges-
1. These dang cheeks!  Every time I try to work one spot, another gets wonky on me, or the circumerferencial shape goes out.  Right now, I'm going to try gluing it all up, painting it solid, and see if I can get away with (gulp) sanding around the seams to make it look nice and clean with my paint.  I'm hoping it looks worse than it is.  I don't like the way that right cheek is flaring out.
2. The headband stretched differently when I shaped it to the ridge, so my perfectly cut 2" strip is no longer so perfectly 2".  You might be able to make out the pencil line above the right brow where I need to sand down.

Right side:

It's a little tall in the center, but overall as smooth a curve as I can achieve.  What say you?
With the ear in place, the tallness isn't quite so obvious.


Back:

The right side (from the back) looks higher than the left.  I will adjust for this when I permanently glue the band in place.  Right now, I just have skinny shims keeping it spaced high enough for a good fit.
I'm pleased with how well the rear plate fits.  Haven't decided on my design for the key holes.


Left:
Nothing here that isn't really noted from the right view.