Best way to cut holes in TIE Fighter helmet for hoses?

[ComposerRyan]

So after much debating with myself, I have decided to cut holes in my precious TIE fighter helmet so that I can fit the hoses in.

What is the best way to do this without damaging the helmet? I am a COMPLETE noob (there I said it ) at doing this and would appreciate any advice.

This is a good example of what I am trying to accomplish...you'll notice that the front of the helmet has holes in it where the hoses can fit:



Thanks guys for your help!

 

[Nagedzi]

Start smallish with a drill bit and then slowly start cutting with lexan scissors or a knife. Check periodically against the hose. Take your time. I actually made mine snug enough that the hose screws into the helmet. Good luck!

 

[matty matt]

I would use a Dremel tool with a sanding drum attachment. Start with a bit you can plunge through the helmet, then widen the hole until you can fit the sanding drum inside. Then it's just a matter of widening the hole until you're done.

 

[blue2k]

Hole cutter attachment for a regular high speed drill. The hole cutter bits come in various sizes, and usually as a pack of 5 or more. Always cut smaller than you actually need the hole to be. You can always enlarge, but rebuilding can be a time consuming process. Alternatively, you can blank off the end of the hose, and hot glue some rare earth magnets inside. This should keep the end of the hose attached to the faceplate (you will also need to add magnets to the inside of the faceplate obviously) without having to drill into it. Needs to be super strong rare earth though, or it will detach.

 

[Shadeling]

I Uni-Bit may help. It's a triangle shaped drill bit that can make holes larger one step at a time


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