First Build: ANH Stormtrooper Helmet FINISHED

Here is a silicone molding video I made years ago
Molding helmet - YouTube

and a quick easy fiberglassing video I did as well
300 Spartan Helmet - YouTube

Hope this helps!

Thanks alot! But one question.

What is that material that you filled first in the silicone mold?

He tells you the steps in the video. First layer is gelcoat. Second layer is "resin mud". The third layer is fiberglass resin, which is (by the looks) fiberglass matting with resin layered inside.

I just asked for the first layer, the gelcoat. I never heard of that before and can't find something that matches.

TheOrdner said:

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I just asked for the first layer, the gelcoat. I never heard of that before and can't find something that matches.

Gelcoat is a thicker polyester resin topcoat.
Try looking at stores that have boat repair stuff. I usually buy gelcoat at bauhaus (yachtcare polysterschlusslack weiss)

Matt Munson just put together a similar video to mine but much better and more detailed. Check it out on his YouTube account

So, yeah. A little update today.

After I finished the Pepakura, I started to fiberglass it.



Thats the result. I kinda like it, but the eyes are a bit.. hm, yeah.
When it was dry, I put some bondo on it.
I used way too much bond, I know...



And thats how it looks after the first hour of hand sanding.



So yeah, that was my work for today. How do you like it? I know, it isn't the best, but I like it.
Any tips what I can fix or do better next time?

Thanks!

That helmet was my first build and i put hours, blood ( literally made myself bleed many times) sweat and tears into it. I always enjoy watch other people build this helmet. Well good luck and have fun.
Here's a link to my old thread it might help.. might not.
http://www.therpf.com/f24/anh-trooper-build-135269/
also check out Terra1's build its the reason i started mine

Thanks a lot!
Your helmet looks very nice and your "diary" helped me alot.

But one question.
How do I close the eyes and the lip for the molding? Fiberglas?

Thanks!

I used some two part general purpose putty that you can find at any hardware store like lowes or home depot

I usually go with loctite. it dries grey and sets hard as a rock in about 5 minutes. you have to work fast but as long as you do a little at a time its really easy to work with and only around $4 a tube.

An update! An update!

Yeah.. after a week of break I started sanding again and thats how it looks right now.
I hope, I can get some tips, clues and hints from the vet's in this forum

i have no idea how terra1 and echo got theres to look so good, IMO the spacecowboy file does not look good to me. im using this one, as it appears more accurate and easier to build/less bondo

ANH_Hero_TK_helmet_unfold_by_Fierfek.pdo - 4shared.com - online file sharing and storage - download

I just read today about something called "Prime Filler"... Lol
It seems very important and I think I need it for my helmet with the surface of the moon.
But, what kind of fillers are there? Differences, colors? Where do I get it?
Thanks!

do you mean spot putty? bondo makes this red stuff, its basically pre-mixed bondo except you have to apply it VERY thin coats. its much more fine and less grainy, you use it to fill in tiny holes/scratches from the bondo. it makes the surface much more smooth for finer sandpaper grains before paint.

oh and be patient it takes time..... lots of it

Thank you all for your help!

So yeah, I spent the whole day filling and sanding with "Leicht Spachtel" (I think Putty Light it is in english).
In some areas it looks nearly nice but others are... hm.
I try to find some lighter putty, so i can fill thos gaps.

On this step, I painted it with some filler (spray putty). Next, I want to add some milliput to the eyes and the huge gaps.

I want to cut out the mic, like terra1 did, and model the whole thing again, because it is to big.

Where should i attach more putty and where should i model more? Any suggestions?

Hi Ordner,
the helmet was my first project too. i just used some other files for the pep.

in germany it is kind of hard to get the whole stuff that is beeing used to make this because the names are simply different.

the best source (in my opinion) PHD-24 - Index.

i'm just a beginner too but, for me, it was the hardest part to find the whole stuff and figure out how to do this.

another problem is that much videos on youtube which give a good tutorial are blocked in germany (due to the music that is played in them).

if you got questions i'll do my best to answer them.

Kannst natürlich auch auf deutsch fragen ... das macht das ganze n bischen einfacher

Thanks Hofnarr for your help and the link

I spent some hours in sanding and filling and I think the general shape is achieved. What do you think? My next step is to fill the little gaps with more fine putty and then add the ears and work on the lip.

I just added the ears :S

Its looking good

Iam currently working on some details.. Just look

Just one quick question: Do I need any thin layer between silicone and helmet? Some kind of releaser spray? Or is the primer the last layer?

You need something called "trennwachs" don'T know what it's called in the US.
it is rely neccesary to seperate the helmet from the silicone