So, this is one of the more sucky parts of the build. I wish I had taken "before" photos to show you what we started working with.
EDIT: I think i found the previous owner. Birdie was this you?
The last owner started cutting out the ears free-handed, and the end result was wavy lines in the cutout. The one nice thing was that on this side the cut was undersized, so I had a lot of room for correction.
Before I go any further, I have to wonder if Ferro's helmet was a "regular." I wonder this because I was surprised at the amount of material I did have to take away for the left ear cluster to fit... and even now, when I feel like I have taken away MORE material than is seen on the original helmets, the cluster BARELY fits. So, be advised, there may be sacrifices you have to make due to the size of the helmet.
With the previous in mind, I started with @noble's template, but it was a bit hard to apply since there was already a cut on my ear. I finally gave up, printed out a number of pics of the original helmet and just eyeballed it.
Another thing I will note is that the left ear cutout almost makes itself. How? In order to try to make it flat and straight, I used a large flat file and began filing away. As you do so, the kidney shape begins to make itself. Conventiently I had an extra casting of the greeblie at the temple and I temporarily hotglued it to the helmet as a reference marker. Using the boom mic hole, the temple greeblie and number of screw holes as markers, I used the flat file to work over the overall shape and I am pretty pleased with it. I will go back once more and check the shape before adding the base platform for the cluster, but overall, considering the sacrifices I feel had to be made due to helmet size, I am pretty happy with this side of the helmet.
EDIT: I think i found the previous owner. Birdie was this you?
The last owner started cutting out the ears free-handed, and the end result was wavy lines in the cutout. The one nice thing was that on this side the cut was undersized, so I had a lot of room for correction.
Before I go any further, I have to wonder if Ferro's helmet was a "regular." I wonder this because I was surprised at the amount of material I did have to take away for the left ear cluster to fit... and even now, when I feel like I have taken away MORE material than is seen on the original helmets, the cluster BARELY fits. So, be advised, there may be sacrifices you have to make due to the size of the helmet.
With the previous in mind, I started with @noble's template, but it was a bit hard to apply since there was already a cut on my ear. I finally gave up, printed out a number of pics of the original helmet and just eyeballed it.
Another thing I will note is that the left ear cutout almost makes itself. How? In order to try to make it flat and straight, I used a large flat file and began filing away. As you do so, the kidney shape begins to make itself. Conventiently I had an extra casting of the greeblie at the temple and I temporarily hotglued it to the helmet as a reference marker. Using the boom mic hole, the temple greeblie and number of screw holes as markers, I used the flat file to work over the overall shape and I am pretty pleased with it. I will go back once more and check the shape before adding the base platform for the cluster, but overall, considering the sacrifices I feel had to be made due to helmet size, I am pretty happy with this side of the helmet.
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