Custom Commissioned Helmets: Build (Finished PG 3) *TANK HELMET BOTTOM PG 3*

[drjag]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

I have fibreglassed with it, you can force down the matting with a silicone brush pretty much the same way as normal brushes do. It's worth trying yourself, I was skeptical at first but I was surprised how effective it is at fibreglassing.

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Like I said, correct me if Im wrong. Haha
Always happy to try new things. Ill definitely give it a go next time. Thanks drjag.

 

[Killtime]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Dtailed: Yes some types of horse/china will grab the glass, but I've either used hot glue in small amounts (depending on what I am doing) to hold it, or used a smaller finer brush Batch work also helps, for my pep reinforcement a stiff brush is perfect for those bits of detail I want to get into. Dunno, I've had paint brushes in my hand for decades now so I've learned to work with it.

drjag: Silicone brushes only ever occured to me once I started visiting these forums, I will definately give them a shot.

Also, what silicone are you using? Some kind of smooth on or one of our local varieties. Here in Perth, to order smooth on stuff or something else from another supplier is about the same price, small differences in volume for purchase as each other.

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

I guess it comes down to what an individual prefers. The silicone brush idea is a good one for anyone though.

I use a generic silicone from who-knows-where overseas. I usually use around shore 30 for most jobs. This stuff is a little thicker (when pouring) than smooth-on I believe, but I work it in with a brush usually so its not a problem for me. I get it at what I feel is a pretty good price.

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Where was I..........ahh, casting.

So where I left off was with a partial casting. As I said, this would become the buck for forming the plastic visor. I took the casting, trimmed it and reinforced it with a bit of fibreglass. I also spent some more time getting a nice even curve and took it all the way to a glossy surface.
To stop the PET from being sucked under the form too much, I cast a plaster backing to sit underneath the buck and provide side walls to pull against. I then pulled a test visor, trimmed it and gave it a few coats of tint to see how it looked on the helmet master. Very nice.



It was finally time to cast a full helmet. I dusted the mould with talcom powder to act as a release and then started the long, painful process of slush-casting by hand. Im yet to build a roto-caster. Thats next on my to do list. Trust me, its definitely next.
I poured one cup at a time in sections around the helmet, starting with the crown and then working in segments around the outer edge. I did it this way (as opposed to applying the resin to all surfaces, evenly, all at once) to minimise air in the intricate vents details. 8 cups in total make up one casting. Each cup is about 3 quaters resin and 1 quater q-cells filler, by volume. This gives me strength but keeps the weight down and makes the resin easier to cut, which helps because preping one of these involves alot of trimming and sanding. You'll see. Here I cast 2 helmets.



Next came all that trimming.
Each helmet requires the following; the front visor trimmed out, the area behind the mouth detail hollowed to fit the area of visor that slips down behind here, the back of each of the vents sanded off to open them, a hole drilling for an led in the rear vent, the holes in the mouth piece drilling out (11 of them), the opening at the bottom trimming and opening neatly, holes drilled for the screws that hold the visor on (3 of them), holes drilled for the led wiring in the projector (2 of those) and holes drilled for the screws that hold the projectors on (4 of those). This takes time. I also pulled to more visors and did a test fit.





After this I filled a few imperfections from the seam line on top of the helmet (the only place that really needs much work) and primed everything. After this I hit them with some black for the base coat.



Thats all for now. More paint to follow.

 

[BRDencklau]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Boosh. Deets, you be killin it. (American slang is Bollocks.) Seriously though, well done.

Sent from my SGH-T989 using Tapatalk

 

[drjag]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

That's some real nice clean work you've done there man, I presume paint is next right? That's the bit I've been looking forward to most.

 

[Athanasios]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Fantastic work!

 

[dasAdam]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

thanks for all the insight to your project so far. one might think that this detailed descriptions and heavy amount of images might be too much as people here have seen the process over and over again BUT in my opinon it is still great to follow these steps

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Thanks guys!
And I know what you mean dasAdam but I know how much I love to see everyone elses build threads. I guess Im posting this thread how Id like others to post theirs. Haha.

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

So on with the painting.....

I didnt document this stage as well as I could have, because I was looking to get everything finished and it seemed the least important part to cover (perhaps Im wrong though).

This piece has a decent amount of masking involved and after the black base coat, thats exactly what happened.
I started by masking off everything that was to remain black, ie, the vents, some face details, etc. At this point I also added in some toothpaste (thought id try it out) as a resist for some deeper weathering.
The first 'colour' to go on was the grey either side of the visor. This same grey was also used in the second layer detail of the rear vents.

Then everything got a few coats of white.



After everything was dry I removed the masking tape and had a look at a few places to see how the toothpaste had worked. Not as well as some other methods in my opinion, but if you had nothing else around....



Then it was time for some rank colours. One helmet would be the lower ranked yellow and the other, the higher ranked blue (theres a whole system for this, you'll just have to wait for the film to find out more).



This rank colour includes stripes on the cheeks that vary for the different ranks.



Then it was time for the blue helmet and for a bit of paint on the projectors. I also tinted the visors here too, ready to be installed



Each of the helmets also has the fictional government's logo on the rear. That was cut via a plotter onto some self adhesive vinyl and then stuck to the helmet and used as a stencil. A resist was used to give it that worn look and also hide any imperfections where the stencil had creased on the compound curve.







After that stage came the electronics, just some simple LEDS on a 3v button cell with a switch for the user, mounted behind the mouthpiece.
Then the piece was weathered and clearcoated and had some padding installed.

That all for now. The next post will be the final beauty shots after everything had some weathering and battle damage to tie it all together.

Stay tuned....

 

[Athanasios]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Again, this build is looking simply marvelous! Can't wait to see the finished result!

 

[dasAdam]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

yes yes yes! decals (logos) add a lot!

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Haha. Thanks guys.

Yeah, decals really add to a piece.

Ill have the finished pics up soon.

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Finally got the time to put up the finished pics. Weathering was done with various washes, drybrushing and airbrushing to simulate battle damage, wear and tear and general dirtiness.

Two initial pieces, one of each rank (blue and yellow). The finshed pieces.......













And the other........













Enjoy!

 

[BRDencklau]

Re: Custom Commissioned Helmet: Scratch Build (LOTS OF PICS)

Thanks guys!
And I know what you mean dasAdam but I know how much I love to see everyone elses build threads. I guess Im posting this thread how Id like others to post theirs. Haha.

You know that is how I roll, Brother.

Sent from my SGH-T989 using Tapatalk

 

[BRDencklau]

Re: Custom Commissioned Helmet: Build *FINISHED PICS PAGE 3*

Oh, EFFING AWESOME.

By the way.

Sent from my SGH-T989 using Tapatalk

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Build *FINISHED PICS PAGE 3*

Haha. Thanks brian. Im looking forward to your next long-winded recount too.

 

[Exanimus]

Re: Custom Commissioned Helmet: Build *FINISHED PICS PAGE 3*

Very nice. How are you tinting the visors, are they dipped in dye? Thanks for posting this.

 

[DtailedREPLICAS]

Re: Custom Commissioned Helmet: Build *FINISHED PICS PAGE 3*

Hi mate. Thanks.

These visors are sprayed with VHT Nightshades. Its tricky to get a good finish but with a bit of practice you can get very good results. I find you can get a darker tint than with a dye, such as RIT.