Boushh Helmet build

Discussion in 'Star Wars Costumes and Props' started by merkava74, May 16, 2015.

  1. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    COMPLETED PHOTOS: post #64

    Had posted this on TDH, but thought I'd do the same here. If the admins think I should not, let me know and I will stop, thanks.

    While waiting for my gadzillion ESB Boba's parts to arrive (likely over the next 3 to 4 months), I decided to start on another helmet project: Boushh. I've always found her (his, since Boushh was supposed to be male, and Leia was only cross dressing) helmet to be cool looking.

    Bought the bucket off Sandman (Todd), and he is a friendly and accommodating guy to work with. Awesome dude!

    The kit came in a nicely sealed box with lots of cushioning, and the packets of resin greeblies neatly packed in ziploc.

    The main attraction, the helmet, was a crisp, smooth and well cast block of resin. Except for the seam that ran through the cross section of the helmet, It was a very nice cast! Truly excited!

    [​IMG]

    And so the project begins.

    I intend to do this slowly, and try to reference this as closely as I can to the screen-used prop, as there are many nice clear photos of it.

    - - - Updated - - -

    The first thing to do was to cut our the visor and the head display slots.

    The visor was pretty straightforward/ You just had to cut straight into the helmet, and take care at the rounded sides. The thing that needed some work was the inside top of the rim was longer than the inside bottom of the rim (not sure if you get what I'm saying), which would result in the visor being tilted backwards when viewed from the side. I wanted the visor to be perpendicular to the slot, so I had to trim the inside of the top rim to get it in line with the bottom rim. Test fitting the visor regularly helped to ensure I did not take away too much, or it would tilt forward!

    For the head display slot, what I did was mask out the area that needed to be cut using graphic tape, and put my dremel to work.

    [​IMG]

    Turned out pretty nice, If I may say so myself! [​IMG]

    [​IMG]

    Now the problem I faced while doing the top display was that after cutting the slot, the visor could not sit neatly against the edge, as the resin inside of the helmet was thick and uneven. I had to use a cutting bit to flatten the inside of the slot in order for the visor to sit.

    As you can see, a photo from the inside showing the flat groove that I created to allow the visor to sit neatly against the slot opening.

    [​IMG]

    The view from the outside showing the neat groove.

    [​IMG]

    The visor had to be trimmed too. It was too high and too long, so both the length and width had to be trimmed to fit into the small space at the display slot.

    [​IMG]

    Finally, a dry fit with the visor in place. Pretty satisfied with how it looks.

    [​IMG]

    - - - Updated - - -

    Next up, I tackled the piece at the front centre of the helmet. The resin part came with a straight edge, so a lot of grinding would be needed to get it to sit nicely with the curve of the top of the helmet. Take note that there is a nub on either side of the resin part. Not sure why Todd casted them. The photos of the SU piece did not have them. So I removed them. The tiny holes running down the centre of the piece were also not found in the original. I will fill them later.

    [​IMG]

    The nubs removed:

    [​IMG]

    - - - Updated - - -

    To know how the curve will be in order to grind the resin piece properly, I masked the contour of the curve, and transferred the masking to the back of the resin piece. The curve is symmetrical and so would be ok even if it was reversed when transferring to the resin piece. This would give me a good guide as to how far the curve went, and take care not to remove too much of it.

    [​IMG]

    The masking transferred to the back of the resin part:

    [​IMG]

    Also, the curved part was lesser at the top than the bottom. So you can't just grind it away vertically following the masking line. You had to angle it a little, which was done with very very very regular test fits. Remember, "measure twice, cut once"!

    This was how it looked after grinding:

    [​IMG]

    The final fit. There is some slight unevenness at the top of the helmet preventing the resin piece from sitting flush with the top. That will be resolved when gluing the piece down.

    [​IMG]
     
    Last edited: Jun 1, 2015
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  2. Notlewis

    Notlewis Active Member

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    Great build so far! Keep up the great work! :popcorn
     
  3. welshwarrior123

    welshwarrior123 Well-Known Member

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    Some really nice prep work you are doing. Ive built up two of sandmans kits and they are beautiful helmets. Cant wait to see how it turns out.
     
  4. Sym-Cha

    Sym-Cha Master Member

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    Great progress sofar ... I always wondered if Leia actually killed Boushh in order to get her hands on the outfit ... or just grabbed it while he was taking a shower after another bounty hunt :wacko

    Chaim
     
  5. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Thanks guys! Yes, Todd's casting is a breeze to work with!

    Haha! Maybe Boushh is somewhere still cuffed to his bed! ;)
     
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  6. bdgr

    bdgr Member

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    Looking great so far. I'm really enjoying your detailed WIP build.
     
  7. Broilermaker

    Broilermaker Sr Member

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    Naw she seduced him and as he lay snoring made off with his clothes
     
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  8. MAAZ

    MAAZ Well-Known Member

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    Great build so far - please keep posting those wip pics :)
     
  9. Trooper_trent

    Trooper_trent Master Member RPF PREMIUM MEMBER

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    Great work so far. Todd has great helmets. I was super impressed with his casts.

    Here's how mine turned out.
    DSC_7885.jpg DSC_7884.jpg
    And if you care to learn from any of my mistakes, here's my thread. http://www.therpf.com/showthread.php?t=223429

    Can't wait to see more! Love it!
     
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  10. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Thanks guys! I hope you guys are enjoying reading as much as I am enjoying the build! Hopefully this can also serve as another reference for future Boushh builders.

    Yes, Trooper_trent, followed your build for the Tusken Raider, and now following your build for Boushh! I love your battle damage on the helmet. Hope mine can turn out as nice!
     
  11. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    So here's the next update.

    Decided to tackle the head antenna thingy. While the supplied part was ok, I wanted to do another one myself. Maybe because I wanted sharper edges, maybe because I wanted rounder tubes, but mainly because I'm * this way. :)

    So this began with sourcing for the right sized tubes and a little bit of thinking behind how to fabricate it, comparing closely with the kit part.

    [​IMG]

    From the main tube, 6 slots were marked out with graphic tape to be cut out:

    [​IMG]

    Slots cut and the tube sanded down to see better:

    [​IMG]

    Next, a larger size tube was cut into 4 rings, one complete ring, and 3 cut further to form 2 arches each. I need 6 of these. The first ring done:

    [​IMG]

    All 6 arches done.

    [​IMG]

    The inside was filled with several tubes of different diameters as per the actual prop, and the hole for the antenna drilled.

    [​IMG]

    I inserted a screw thread on the back for easy installation into the helmet later:

    [​IMG]

    The completed part primed:

    [​IMG]

    [​IMG]

    That's all for today. Gonna be travelling for work for a week, so won't be able to continue this till next week. In the meantime, if anyone can help me to identify the metal greeblies that go on the end of the antenna as shown, that would be awesome!

    Those metal things along the rod. What are they and where can I find them?

    [​IMG]
     
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  12. Katscan

    Katscan Member

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    That metal piston is the same prop used for C3PO's chest pistons. Well, part of it anyway!

    [​IMG]
     
    Last edited: May 17, 2015
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  13. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    thanks!!! You're a lifesaver!!
     
  14. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Had some time this morning to tackle the dent on the top of the helmet as seen in the screen-used one:

    [​IMG]

    Marked it out and ground it down. Good thing Todd's helmet is thick in this area, so no filling is needed as it did not go through the helmet:

    [​IMG]

    The completed dent:

    [​IMG]

    Now for the battle scars!
     
  15. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Battle scars added! Had so much fun that I had to remind myself not to overdo it! :)

    [​IMG]

    [​IMG]
     
  16. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    The right ear greeblies done. Had to deviate from the instructions, which called for an acrylic plate to support the pieces. After looking at the photos of the original, it seems that it's actually a box-like thing under all that. Also, the greeblies were "fused" to the underside of the helmet, including the tube that went into the helmet. Wrapped some epoxy putty around that to simulate the fusion. Would have to sand it down later for a more natural look.

    [​IMG]

    [​IMG]

    The lower tube is also supposed to enter the helmet at both ends. one end had to be rounded down to simulate that as it would be tough to try and heat and bend that exactly:
    [​IMG]
     
  17. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Left ear greeblies done. Pretty much the same as the right, except that the squarish greeblie is inverted, and the kit is missing a box-like thing at the back as per the original.

    [​IMG]

    [​IMG]

    [​IMG]

    What's left now is to wait for the epoxy putty to dry, sand the whole helmet down again, and prepare for the paint job!
     
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  18. Katscan

    Katscan Member

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    Aww, I was hoping to catch you before you began on the ear greeblies. I had been doing some research on the different parts that had not been identified and found a few.

    http://www.thedentedhelmet.com/f68/boushh-works-48307/

    In the end, two pieces I couldnt identify, I prototyped them and 3D printed them.
     
  19. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Haha! Just saw your thread, and yes, those 2 rivets stumped me too. But I figured since they were at the bottom, I'm gonna go th cheat route and just find some round discs. :)
     
  20. Coop

    Coop Sr Member RPF PREMIUM MEMBER

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    Fantastic job on the weathering so far. This thread has really giving me a new appreciation for this helmet. Can't wait to see the finished piece.
     
  21. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Thanks! But ermm... I haven't started painting yet? What weathering are you referring to? Or do you mean the physical weathering? ;)
     
  22. Coop

    Coop Sr Member RPF PREMIUM MEMBER

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    Yes, the physical "damage", so to speak.
     
  23. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Ahh, thanks! It was addictive adding the scars, trust me! ;)

    Sadly im overseas for a week, so will not be able to do any more until this weekend.
     
  24. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    So while overseas and unable to continue on my project, I did further research and lo and behold, discovered that I had made a mistake with one of the battle scars! They were streaking in the wrong direction! Something I need to remedy when I get back:

    [​IMG]
     
  25. Trooper_trent

    Trooper_trent Master Member RPF PREMIUM MEMBER

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    AAARRRGGG!!
    nobody will notice but you, but I totally get the frustration.
     
  26. themacalu

    themacalu New Member

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    I have the same kit from Todd! Thanks for the very detailed walkthrough!
     
  27. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Exactly! It willl bug me for eternity every time I look at it. So I have to fill it up and cut the other direction. :)
     
  28. Katscan

    Katscan Member

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    So, you may want to consider using a 2 part putty (sometimes reffered to green or grey stuff) to fill gaps and fix mistakes. Guessing you have been using plastico or something like it?
     
  29. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Yes, the 2 part epoxy putty that I am using is the Tamiya one. Really great quality, hard and smooth drying:

    [​IMG]
     
  30. Katscan

    Katscan Member

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    Ahh very nice! It looked like plastico for a moment there :$

    I will need to take pictures of my build, Ive stalled for the moment as I am having trouble finding leather. Also trying to build my own electronics for the visor, along with fans to help keep the wife comfortable while wearing the bucket.
     
  31. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Yes the leather is a tricky one. I scoured high and low to find this (see the inset picture):

    [​IMG]



    It is a 2mm thick calf leather, that in my opinion most closely resembles the base colour of the actual leather. Here are a couple of things I concluded when looking at the original:

    1. The snout is a thinner one compared to the back covering piece and the strap. The snout also has a smoother texture compared to the back piece. The back is definitely cowhide, as can be seen by the texture, but for the life of me, I couldn't find cowhide that is exactly the same colour as the snout leather that I found. As such, I will be folding 2 pieces together to simulate the thickness.

    2. The original piece reveals a lighter tan colour when scratched. When I tried to scratch mine, the colour doesn't get much lighter. I guess when I come to it, I will scratch the leather, rub in a tan colour, and blend it in. Hopefully I can get it as realistic as possible. I really like the base colour of the leather that I found, so I will weather it from this starting point. I am foreseeing several tones of greys, browns, tans and oranges.

    I do have a pretty big piece of leather, and if you are keen, we can work something out.
     
    Last edited: May 20, 2015
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  32. Trooper_trent

    Trooper_trent Master Member RPF PREMIUM MEMBER

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    FYI!!! the calf hide recommended in the Kit instructions is the correct thickness. Get and non-dyed hide. When you wet it to soften it up so that it wraps, it will darken. Then you can use oil or just rub it with you hands to get the correct color and sheen. Check out the pics on my thread of when I first put the leather on. Just getting it wet darkened it a lot. The original leather was very light and unstained.
     
  33. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Yes I figured it was non dyed to begin with. But where I come from, we don't get that. So had to look for one with the closest resemblance.
     
    Last edited: May 20, 2015
  34. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Have not been able to continue the helmet over the last week as I was overseas, and now that I'm back, I'm a little busy with other projects and errands. Nevertheless, here's a little update:

    Thanks to Katscan, I ordered the C3PO part for the Boushh Rangefinder antenna thingy. It arrived today, and here it is:

    [​IMG]

    To be honest, I've never ordered 3D printed stuff before, and I'm quite puzzled by the grainy feel to it. It's not outright rough, but not smooth either. Luckily, this is a small part, and then only part of it will be used (red rectangle), there are only a few areas that need to be smoothened out. I'll see how it goes when I get to it.
     
    Last edited: May 26, 2015
  35. spoudastis

    spoudastis Well-Known Member RPF PREMIUM MEMBER

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    Ya, looks like it was done on an SLS machine which laser sinters plastic powder together as opposed to an SLA which does the same except the laser cures resin. The SLA is much smoother however the SLS is very strong. For this small part with lots of fine detail the SLA should have been used, hopefully your part is still usable.
     
  36. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Funny thing is, I ordered this from Shapeways, and specifically chose this:
    [h=5]
    Polished Metallic Plastic
    [/h]Grey nylon plastic with a subtle metallic sparkle and polished sheen (formerly Polished Alumide.)

    But apparently it came more like this:


    [h=5]White Strong & Flexible[/h]White nylon plastic with a matte finish and slight grainy feel.

    I have sent an email to Shapeways for clarification. Let's see what they say.

    Worst case, I can slightly bondo the part, or scratch build it, but I'm just not feeling the love at this moment.
     
    Last edited by a moderator: Nov 9, 2018
  37. superbill22

    superbill22 New Member

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    If anyone is in the area, the original Boushh costume (along with a ton of others from SW) is currently on display at the EMP Museum in Seattle Washington until October
     
  38. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Unfortunately, I am in Singapore, on the other side of the planet. Take more photos!

    So here's a little update:

    Masked up the parts where the leather will go, so that the paint won't screw up the adhering of the leather to the helmet, and primed. Discovered some areas where more sanding is needed.

    [​IMG]

    [​IMG]
     
  39. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    And here we go with the smoothening up of some areas. And yes, I corrected the wrong-directioned battle damage on the front left rim. ;)

    [​IMG]
     
  40. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    So while waiting for the filler to dry, I decided to make the templates for the markings on the helmet.

    I made them on my Silhouette Cameo for cutting later, and saved it as a jpg for anyone to download and scale to your needs. Do note that in the actual helmet, the markings are made by sticking vinyl onto the helmet directly, and not airbrushed on. I leave it up to you to decide how you want to apply it, spray or stick. Enjoy!

    [​IMG]
     
  41. Saberbay

    Saberbay Active Member RPF PREMIUM MEMBER

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    Always loved this design, you are doing MAJOR justice to it
     
  42. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Thanks! I'm enjoying the build very much! Yes absolutely love the Boushh helmet!
     
  43. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Sanded down again, washed with mild soap and letting dry. Looks like a step back, but it's really a step forward. You want to get the surface free of imperfections so that the paintwork will be nice and smooth later. Now we are ready for priming, and painting of this beautiful bucket!

    [​IMG]
     
  44. Katscan

    Katscan Member

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    Before you do any more painting I would either glue the top piece on the bucket or temporary secure it to the top so that you dont have to sand away the paint to glue it on later.
     
  45. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Yes I intend to do that! Thanks for the reminder, though!
     
  46. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    So while preparing for the paint job, I took a closer look at the original and how the layers went on, and it was pretty random, with some colours going on before AND after some other layers, as seen below. Will do the best I can!

    [​IMG]
     
  47. Katscan

    Katscan Member

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    Keep in mind that some of that coloring may be due to environment from being in storage. Also, those black bands(around the dome ontop and on the back) are black pinstripe(decals).
     
  48. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    Yes, but I'm trying to replicate that as much as I can. The black bands (1 on the top round and 1 on the front rim) are graphic tape stickers. They are too thick for decals.
     
  49. merkava74

    merkava74 Sr Member RPF PREMIUM MEMBER

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    So this is going to be a long post.

    I started painting today, and got quite good progress. I used Tamiya Enamel paints, and don't really have a sequence of painting, using both topical and layering, as well as toning and misting, dry brushing and oil washes.

    For this helmet, I'm not trying to get every scratch replicated, but more the feel of the original bounty hunter: weathered, unkept, and functional.

    So on with the painting. After a final primer and sanding down and primer again, I applied the base coat of Flat Brown with about 40% black. I like a very dark base to give me the depth later:

    [​IMG]

    After the base was applied, I toned it with Flat brown (without Black) to give it some depth. It will turn out much lighter at this stage, but I know I will be toning it with various darker layers later. This is a shot of the toning in progress, showing the top half with the base coat and the lower half toned:

    [​IMG]

    This is after the first toning. As I said, it is light, but I wanted to make sure there was the greatest contrast between this and the base coat:

    [​IMG]

    The next toning layer was Red Brown, now bringing the colour back up, but also showing hints of the lighter tone underneath:

    [​IMG]

    The paint chips were hand painted using Red Brown with 40% white added:

    [​IMG]

    [​IMG]

    [​IMG]

    Next, Sky Grey was used to mist the back portion of the helmet:

    [​IMG]

    After Sky Grey, I used German Grey to further tone the dark areas:

    [​IMG]

    [​IMG]

    Then Black was used directly to mist certain areas of the helmet to give it a little of that burnt / charred effect:

    [​IMG]

    When that was completed, it was time to hand paint the silver paint chips and scratches. I used Flat Aluminium for this:

    [​IMG]

    The top rim was also sprayed with Flat Aluminium:

    [​IMG]

    The ears were also sprayed with Black, and dry-brushed with Flat Aluminium:

    [​IMG]

    Now the whole helmet was dry-brushed with Flat Aluminium, and then misted with German Grey to dull down the bright silver colours. The 2 black vinyl strips were also added:

    [​IMG]

    Using my Silhouette Cameo, the stencil mask for the right of the helmet was cut and positioned for spraying with Hull Red:

    [​IMG]

    I chose this very dull colour intentionally to have a worn and faded effect:

    [​IMG]

    The left side done too:

    [​IMG]

    [​IMG]

    The back was a little more tricky as the line is not straight:

    [​IMG]

    [​IMG]

    I am pretty satisfied with the progress today. Here are the photos so far, after they were sealed with a matt Clear Coat:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    The next step will be to apply washes to give it even more depth, and more dry-brushing and toning before I call it complete for this part of the helmet.
     
    Last edited: May 30, 2015
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  50. Mean Obiwan

    Mean Obiwan Well-Known Member

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    * that's a sick paint job! Really killer build, and doing great justice to the original prop.
     
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