Boba Fett Polystyrene Helmet

I started my next project after I finished my pepakura Stormtrooper bucket. I used the great templates from thedentedhelmet.com and made the boba fett helmet out of polystyrene and epoxy-fiberglass.

A little update on my styrene boba fett helmet. I almost finished the epoxy putty - sanding work and started the ears.

Very cool. To get the bends, did you score it and then fold or did you heat it? (I'm very new to all this so forgive me if it's a stupid question)

KidHaru said:

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Very cool. To get the bends, did you score it and then fold or did you heat it?

No I didn´t score or heat it. I used 0.5mm thick styrene. Its flexible enough to get a nice curve.
I just needed a little epoxy filler at the edges because of little heat deformations from the use of hot glue in this area.

Oh, and there are no stupid questions! I am also new to this and I am glad if I can answer some questions

Awesome! Thanks! I noticed the inside of the helmet on the 2nd picture is very thick. What is that exactly? It looks like a large cylinder that you then used to form the styrene around. But then it's also fiber glassed in so It's permanent. Or is it simply a folded lip at the top?

Looking good there, need to finish mine.

KidHaru said:

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Awesome! Thanks! I noticed the inside of the helmet on the 2nd picture is very thick. What is that exactly? It looks like a large cylinder that you then used to form the styrene around. But then it's also fiber glassed in so It's permanent. Or is it simply a folded lip at the top?

No its just a frame made of 1,5mm thick styrene to keep the right shape of the helmet until the fiber glass is hard.
I removed all frames (also the dome frame) with a Dremel afterwards.

Super job Alonzo Fonzo! I look forward to seeing the final product!

I used the same template to do a scaled down helmet for my son.

your ears look so sharp nice job

Thanks for your nice comments guys!
Today I made the rangefinder inner part out of clear polyester resin. It´s still in the silicon form I made to cure.

I added all the ears and small details. Some sanding need to be done and then it should be ready for the first coat of primer.

I started painting the helmet. I am using Humbrol paints and my airbrush.

Sweet looking helmet, the proportions are really good for a scratch built helmet. Good job man.

Thanks.
I almost finished the liquid masking and painting of all the different colour layers. Next step is to add all scratches, dirt and other details

looking really good.

Holy horses! thats awesome. I was trying to find some thing to do with the rest of my styrene and I thought of boba fett armor, but I couldn't figure out how to do it and make the curves. Now I know. By the way: nice paint job!

Wow! Looking very good!

Thanks!
I am almost finished but I lost the top part of the range finder side ear somewhere . I had to make a new one...
So only a little setback

Looks great!

Wow, that's coming along great!

One of these days I'm going to actually attempt something like this...

I built one of those using the same templates, you have done a very nice job so far, it looks great !

Thanks for the comments guys!

Finished!
I finally found the time to add the flashing LED´s and white back-light in the Rangefinder.
I hope you like the result and thanks for looking!

That is really awesome.....congrats

Beautiful!

Well done! Turned out nicely, and awesome paintjob!