Complete Rubies kids X-Wing pilot costume TFA helmet conversion

mmhnc

Well-Known Member
Since I'm waiting for paint to dry on my 5 year olds battle droid costume I figured it was time to start modifying this store bought X-Wing pilot costume for my 3 year old. Now I know I should have scratch built this and I'm sure there are small orange coveralls out there somewhere but I figured hey it's a starting point and I'm going to modify it anyway.
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So when it arrived we tried it on, the flight suit is actually not bad, it has boot covers built in and they are going to have to be shortened as they are way to long. The vest is ok too.

Now as far as the helmet and chest box go the paint is YIKES! Seriously it looks Ike some one painted them with there eyes closed while falling asleep on a train. There are even spots that look like someone dropped a brush on it.
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So knowing all to well I was going to need to mod this I asked my son what kind of paint he wanted, he tells me he wants the black and red helmet from the commercials we have been watching...... So now we are doing a force awakens build. I'm sure everyone knows what we are talking about but here is reference any way.
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Now the shape of the helmet is all wrong from the original trilogy so we are going to be doing some cutting and glueing.
first here is the helmet as it came out of the box, it's in 2 halves that are held together with Velcro, along with a visor that is Velcroed on. You can't actually see through the visor because it is painted a translucent yellow becuse you know why do kids need to see while trick or treating.
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So the new helmet has a little bit of the Mohawk still in the back so we will only save that little bit
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So I managed to do this and only stab myself in the finger once. Next I will have to reduce the raised top sections but that will be a post for another day.
 
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Re: Modified Rubies kids X-Wing pilot costume

Ok cut the helmet up a little more last night, first I sectioned the raised sections from both sides
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Then I separated the vertical walls from the horizontal ones on the first side
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I'm wondering if it will be best to glue this back together and then fiberglass.

Question! I know other people have modified Rubies helmets, so how would you normally reinforce one of these?
 
Re: Modified Rubies kids X-Wing pilot costume

I used Bondo on my Jango Fett 2-piece, which is a Rubies, for a build I'm doing for the Mercs. Others have used zap-a-gap and fiberglass.

Jenn (kornishpyxee)

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Incidentally, I'm glad you posted this, because I was contemplating getting the adult costume and doing the same with its helmet.

Jenn (kornishpyxee)
 
Re: Modified Rubies kids X-Wing pilot costume

Go for it I would love to see how you handle the build compared to mine.
 
Re: Modified Rubies kids X-Wing pilot costume

Last night I was able to start fitting all the pieces from 1 side back together, it's real ruff right now but this is the initial fitting. Clearly there needs to be lots of trimming and filling before I try to fiberglass this.
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Re: Modified Rubies kids X-Wing pilot costume

Subscribed! I love these types of projects. I'm really interested in how this turns out. Best of luck!
 
Re: Modified Rubies kids X-Wing pilot costume

Ok so I have the first half of the helmet almost all glued back together. To do this I filled the large gaps with some styrene along with remaking the center strip in 3 pieces to go along the little Mohawk bump in the back. I then used CA glue, baking soda and accelerator to glue and fill the smaller gaps. The backing soda reinforces the glue and allows it to traverse a gap better. I left a couple ends of the center strip unglued so O can make adjustments when I join the other side.
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Re: Modified Rubies kids X-Wing pilot costume

And there you have it! It's back into 2 halves, just a bit more filling and joining together and we will have turned an orignal series X-Wing helmet into a force awakens X-Wing helmet. Well not exactly, I still need the ear pieces the mic extensions and the blast shield, but hey small accomplishments need to be celibrated too.
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Re: Modified Rubies kids X-Wing pilot costume

Well well well, would you look at that. I now have a 1 piece helmet in the shape of the new one from Episode 7. I have a lot of filing to do on all the seams and I still need to fiberglass the inside. But I did have to take a moment and appreciate this.
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Re: Modified Rubies kids X-Wing pilot costume

Got the cheek extensions done, had to remove a section to get them to sit flat but I think I got the shape about right.
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Also started the templet for the blast shield and visor, will update those soon
 
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Re: Modified Rubies kids X-Wing pilot costume

No picks becuse it's still drying but got the helmet all fiberglassed tonight. We will see how it came out in the morning.
 
Re: Modified Rubies kids X-Wing pilot costume

So the fiberglass came out ok, I decided to use my left over Plasti Dip on the inside of the helmet to prevent any of the fiberglass from irritating his head. My 3 year old was so excited that his helmet was finaly getting painted he wanted to help this afternoon. A 3 year old with a can of spray paint what could go wrong?

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After sending this super cuite picture to my family my sister returns this about 30 minutes later.
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What can I say, the force is strong in my family.
 
Re: Modified Rubies kids X-Wing pilot costume

I'm disappointed in you guys, that last one should have gotten a reaction.... Tisk Tisk
 
Re: Modified Rubies kids X-Wing pilot costume

Base layer of primer/filler done (4 coats) wishing I would have done another layer of resin over the fiberglass as its a little ruff. Going to to start sanding and bondo tonight.
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Re: Modified Rubies kids X-Wing pilot costume

Looking good! Can't wait to see the finished product.
 
Re: Modified Rubies kids X-Wing pilot costume

Lots of sanding, another coat of primer/filler and a guide coat so I can find the highs and lows. A little aggressive sanding on the worst lows and I will be ready for Bondo.
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Re: Modified Rubies kids X-Wing pilot costume

On the final push!
got all the Bondo smoothed on the helmet, now need to spray a guide coat so I can find all the small holes and low spots.
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I also finished the gloves.
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Re: Modified Rubies kids X-Wing pilot costume WIP

Helmet all in black with the ear cups added, kind of wishing I put these on before adding black and spent time molding them in. But for now this is how they lookimage.jpg.
 
Re: Modified Rubies kids X-Wing pilot costume WIP

Paint all done, now just to add the stencils (most of them are in the picture).
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