Darth Vader Helmet (and other nicknacks)

[kingofsouls]

Well, this is the first "heres my build prgoress" thread here, so here's hoping I'm doing it right.

So, little background information on this one: My sister likes Star Wars, and for her birthday I wanted to make her something really special, unqiue, and a little mind blowing. A movie or something else from the store is nice, but why be ordinary when you can be extraordinary?

That is why I am making her a helmet of Darth Vader.

The first couple of steps was...lets say rough/learning experience. Using JFcustom's Foam Darth Vader as a template and DIY Dali's wonderful Youtube vids as a sort of guide, I set off on my quest.

What followed was using cardboard without making paper prototypes, making helmets too large, pain in the ass resizing, and lots of errors and revelations.

I don't have pictures of the early process, but I do have what I have so far: The Helmet with all the pieces attached. Finally found a pretty close size, and not attaching the back parts of the mask part so it's mork mask like helped a bit.



Only slight problem is...



...I haven't "attached" the pieces yet. I am reasonably sure that if I clue the big cap to the mask part, then it would be really hard to actually put on the whole thing, so, with much hesitation, the plan is to use Velcro for ease of wearing, and to stop the big cap from wiggling.




Here are some pics of me messing about, to give a general idea.

What's next for the project? I am going to cover it with Paper Mache, then apply wall plaster.

Moving on, heres a little side project:



Lucina's mask from Fire Emblem Awakening. I've already begun the paper mache part, but I'm not sure if I should use wall plaster (Which will probably make it hard to bend, so I need to bend it before hand) or just use more paper mache.

 

[Prefect42]

I really like your progress.

I've used velcro for various projects in the past. Might I suggest, given the material you are using, test how much work it takes to separate the velcro before going with your finished helmet. I find it's a thin line between "not enough" and "way too much" hold.

Keep up the good work. Your sister is in for quite a gift.

Ted.

 

[kingofsouls]

Thanks. I just finished a session of work on the helmet. So far I got both parts of the helmet covered in paper mache. No pics because sister is in the house. However, my next step is to plaster the helmets.

Having never worked with plaster before, I am a little stumped. Dali-DIY - my guide - seems to use a powder mixed with glue and water. I however just have a tub of filler plaster. Not sure if I should head out and get some powder plaster or not. Any plaster experts around?

 

[Rogviler]

As long as it's water-soluble you can mix it with glue (white or yellow). Though I'll warn you that I once made a mixture of Durham's Water Putty (similar to plaster) and yellow wood glue and it was basically impossible to sand. White glue is easier, but I would still go easy on it at first and test it.

Also, I don't know how sturdy you made your paper mache, but lately I've been doing a top layer of blue shop towels and slightly watered down white glue and it sets up nice and hard. Keeps it from having that squishy pinata feeling. The shop towels also stretch and bend so you don't have creases like newspaper. If they didn't have a bit of a texture to them they would be perfect, but they'll get you close enough that you don't have to add too much filler to smooth things out.

-Rog

 

[kingofsouls]

As long as it's water-soluble you can mix it with glue (white or yellow). Though I'll warn you that I once made a mixture of Durham's Water Putty (similar to plaster) and yellow wood glue and it was basically impossible to sand. White glue is easier, but I would still go easy on it at first and test it.

Also, I don't know how sturdy you made your paper mache, but lately I've been doing a top layer of blue shop towels and slightly watered down white glue and it sets up nice and hard. Keeps it from having that squishy pinata feeling. The shop towels also stretch and bend so you don't have creases like newspaper. If they didn't have a bit of a texture to them they would be perfect, but they'll get you close enough that you don't have to add too much filler to smooth things out.

-Rog

Even if it is apparently pre-mixed? Okay, sounds solid. How much glue and water should I use? My guideline video uses some water and pvc glue.
BTW, here is the tub of plaster in question, just in case:

 

[Rogviler]

I'm sure that's water based. You'll know if it says "clean up with soap and water." If it says to use mineral spirits or acetone or something else then no.

I would try 1/4 cup of the filler to a tablespoon of glue, then as much water as needed to help it spread easily. See how that sets and how easy it is to sand. If it's too brittle, add more glue.

-Rog

 

[kingofsouls]

Thanks Rog. you are credit to team!

I checked the label, it says to clean up with soap and water if it gets on your skin, so I am guessing we are good there. I'm just a little nervous because from just reading the label it sounds dangerous even though it probably isn't.

 

[kingofsouls]

So, yesterday I paper mached the helmet, and here is how it turned out:



In my personal opinion I think it came out well.

Moving on, I decided to test my skills at using plaster on one of the oversized cardboard lid helmet thing I call my practice dummy. It's not glued well together, but seeign how it's only still around for me to test on in the first place, I see no reason wy not to fix it.




After letting it dry for, eh about 3 hours, I sanded it. All it all it came out smoothly. I used one layter of plaster mixed with glue and a little water, spreading it around and trying to get it thick enough to cover up the newspaper so nothing sees though. For the most part, I succeeded on that front.

Only problem is I need to get more plaster. Anyone recommend what they like to use? Post pics so I can see the brand so I know what to look for btw.

 

[Rogviler]

http://waterputty.com/

Just because it's so versatile. It's a dry powder so you can mix it with whatever you want. It also doesn't come with any scary warnings.

-Rog

 

[kingofsouls]

Thanks again Rogviler!

 

[kingofsouls]

Progress report time!

Using the Durham's Rock Hard Water Putty, I get to work, and now I show the fruits of my labors!



As you can see...lessons were learned the hard way.

After drying it's a little rough, and sanding it with sandpaper doesn't really get rid of the bumps and large splotches of putty. I am seriously tempted to get a motorized sanding tool, put it on low, and sand it that way, but fear the results.

We're gonna take it slow for the next part.

 

[omel]

your sister is gonna love you for this! i made a pep Vader mask a couple of years ago using Fierfek's pep file ( have a build thread here,Vader on Budget if i recall, will check), used duct tape inside the mask to stiffen it up and applied epoxy clay on the outsdie ( dont have fiberglass skills hehe), turned out pretty ok. good luck on your build...keep going

 

[kingofsouls]

Thanks friend! If things keep going as well as they are I should be done in a few days, and that means at least 1 month until her birthday.

As for dancing, any tips for sanding down the big blemishes?

 

[omel]

Thanks friend! If things keep going as well as they are I should be done in a few days, and that means at least 1 month until her birthday.

As for dancing, any tips for sanding down the big blemishes?

Not a fan of bondo ( hated the sanding, then sanding then more sanding part hahaha) , but eventually it will be smooth enough , just had to be patient till i got the bumps sanded down. started with rougher grit moving slooooowly to finer grit sandpaper. a motorized rotary tool would help a lot ..

 

[Rogviler]

You've definitely run into the no-fun part of ANY prop build, which is the sanding. The only thing I can say is go with a coarse grit, like 80, and steel yourself for the process. I usually make my own sanding blocks out of EVA foam (same thing some people make costumes out of), which is easy to cut to any size or shape. Then I attach the sandpaper with rubber cement.

If you are really having a hard time sanding it then you'll want to back off on the glue the next time you mix up your filler.

-Rog

 

[kingofsouls]

The glue helps in keeping it together though right?

 

[Rogviler]

The glue makes it less brittle but also harder, so just use less glue if you can't sand it easily..

-Rog

 

[kingofsouls]

Well I'm back, and guess what?



Yea, It looks pretty good. And she loves it! So win win!

 

[Rogviler]

Nice! Hey, if you want lenses and have a dollar store (the real kind, where everything's a dollar), their sunglasses work great.

Glad to see you finished it, I've been thinking about your project recently and wondered how it turned out.

-Rog