Dex's Y-Wing Helmet Scratch build

Discussion in 'Star Wars Costumes and Props' started by DexJay, Feb 27, 2012.

  1. DexJay

    DexJay Member

    Trophy Points:
    191
    Hello all,
    I’ve been slowly adding to my build over on thedentedhelmet for a while now and I really should have started a thread over here sooner, but there you go! This won’t be a complete reposting (no point in that) so I’ll add more detail and use some pics that you won’t have seen before.

    I’ve always found the Y-Wing ROTJ helmet a cool shaped piece and wanted one for a while. I almost went for a RA kit, but thought, well as I’m doing a Fine Art Masters Degree and am reasonable with my hands I’d try my first sculpt and see how it goes… I started with the best reference pics I could find over on Flickr and made a few friends over there in the process. Hi Frank! (y-wingfighter) and Uncle HeMan! With some good reference shots side on ¾’s and front I thought I’d draw up in Adobe Illustrator as good a reference as I could to start me off. I started a build using 3DSMax model to help me get familiar with the shapes and see how close I could get it really. I was never going down the 3D prototyping route, but might have been nice!

    My Y-Wing Helmet Plans | Flickr - Photo Sharing!
    3D render | Flickr - Photo Sharing!

    After collecting about 5 motorcycle helmets at Car boot sales (Junkyard/Flea Market sales to my American friends!) I went with Medium in size and something that in profile at least might help me build the buck with as little trouble as possible. I removed all the junk – visor, internals and made some reference points to try to make sure I didn’t get too lost on the way! Then with Photoshop, photos and more reference I planned as to roughly where the cuts were going. Then it was out with a cutting disc and start slicing the helmet up. With the chin section now loose I could see where the chunk would go, tape it into place and go from there….

    Novak | Flickr - Photo Sharing!
    Novak planned cuts | Flickr - Photo Sharing!
    Novak Cut up | Flickr - Photo Sharing!

    Rich
    To be continued!
     
  2. ywingfighter

    ywingfighter Well-Known Member

    Trophy Points:
    747
    Hi Rich,
    great to see your new thread here!
     
  3. DexJay

    DexJay Member

    Trophy Points:
    191
    Hi!
    Have I linked the images correctly? Is there any reason I can't see the images and only see the links? Do let me know if this needs editing!
     
  4. DexJay

    DexJay Member

    Trophy Points:
    191
    Hi all,
    Using tubes of mastic from a caulking gun, the chin section now bonded into placed and the gap filled with offcuts. Once cured, it was time to get it a bit closer.

    Jaw modified | Flickr - Photo Sharing!
    Brow & more chin mods | Flickr - Photo Sharing!
    Side view | Flickr - Photo Sharing!

    The brow needed both pinching in and the chin section had too large a gap (the internal opening).With more cutting the brow was moved back the internal area closed up. In profile view it was heading in the right direction!

    Next after a decent sanding back, to make sure the filler/paste would adhere properly, I filled all gaps left by the cutting. Using fibreglass bumper (fender) repair paste I concentrated on the lower area of the helmet.

    filling step 1 | Flickr - Photo Sharing!
    Sanding Step 1 | Flickr - Photo Sharing!

    Remember I’m just after as good a buck as I can make for casting so the insides of the helmet really didn’t matter. It’s a good job too and with the addition of all the filler & fibreglass it was starting to get heavy!

    Until next time!
     
  5. DexJay

    DexJay Member

    Trophy Points:
    191
    Hi all,

    Here's all the images from the previous post as I incorrectly attached them!

    Dex
     
  6. DexJay

    DexJay Member

    Trophy Points:
    191
    Hi all,
    Using tubes of mastic from a caulking gun, the chin section now bonded into placed and the gap filled with offcuts. Once cured, it was time to get it a bit closer.

    The brow needed both pinching in and the chin section had too large a gap (the internal opening).With more cutting the brow was moved back the internal area closed up. In profile view it was heading in the right direction!

    Next after a decent sanding back, to make sure the filler/paste would adhere properly, I filled all gaps left by the cutting. Using fibreglass bumper (fender) repair paste I concentrated on the lower area of the helmet.

    Remember I’m just after as good a buck as I can make for casting so the insides of the helmet really didn’t matter. It’s a good job too and with the addition of all the filler & fibreglass it was starting to get heavy!

    Until next time!
     
  7. DaddyfromNaboo

    DaddyfromNaboo Master Member RPF PREMIUM MEMBER

    Trophy Points:
    4,116
    Hi Dex,

    interesting build, keep on truckin ;)

    My first X-Wing helmet was built using a very similar method, we did not have a lot of ref back in the days in 1997. People were still assuming that the helmets were built with football helmets as a basis, so we went with the next best thing, motorcycle helmets as well. It definitely works ;)
     
  8. DexJay

    DexJay Member

    Trophy Points:
    191
    Hi,
    Thanks! The build is all done finished, so I know this is all a little backwards!

    After the fibreglass paste I added a good few fills of automotive body filler. Also I started to work on getting a nice even return around the edge of the helmet.

    After much of this I trimmed a strip of styrene for the brow section and trial clamped it into place. To give it some added strength I used expanding foam underneath this.

    Once all bonded and cured I sanded and began filling the brow and blending the shape, whilst keeping the step behind the brow where it drops down.

    I looked like it might be OK after all! :)

    Dex
     
  9. ywingfighter

    ywingfighter Well-Known Member

    Trophy Points:
    747
    Hi Dex,
    very great work!:)
     
  10. terryr

    terryr Sr Member

    Trophy Points:
    2,147
    Good use of old helmets.
     
  11. DexJay

    DexJay Member

    Trophy Points:
    191
    With most of the big sculpting done around the front, I started looking at the back. The Y-Wing ROTJ helmet is quite long here and the only way to fill such a large area was to cut the back lower section off. I was going to reattach the cut section, but instead decided on putting in a piece off another scrap helmet. Once this was spaced back and bonded I added a styrene strip horizontally and added expanding foam (for the rear band section) and filled.

    After much sanding and filling the general shape was getting there! It still needed some tweaking, a pinching in of the frontal top area, more adding to the rear band and general symmetry. By this state I was beginning to feel it was definitely heading in the right direction!

    Here's comparison for scale with another Medium sized motorcycle helmet.
     
  12. GrahamT

    GrahamT Member

    Trophy Points:
    191
    Hey Dex, did this ever become a kit? Have been off world for a while ;)
     
  13. DexJay

    DexJay Member

    Trophy Points:
    191
  14. DexJay

    DexJay Member

    Trophy Points:
    191
    Right, where did I get up to?

    I didn't realise that I'd neglected this build up documentation for too long!:facepalm

    After the previous stage I added a good dose of primer (hi-build) to help get a better idea of where I was with the shaping...

    View attachment 109951

    Not looking too bad, I still had to address the rear lip (which flips up) and the lower return section. That I did next.

    View attachment 109952

    You can see on the lower section of the next photo the angled chamfer that I was after. A little triangular section which I had to get right.

    View attachment 109953

    With that about done I started mocking up the button positions on the rear section. Also the audio control (?) at the front where the Yamaha engine cover was used....

    View attachment 109954
    View attachment 109955

    After taking a hole saw through the neck section (sweaty palm moment that one! Don't mess it up! Don't mess it up!) I bonded some MDF onto the inside.
    The inside really didn't matter how messy it got as long as it was solid.

    ..and boy was this thing putting on weight! :lol

    View attachment 109956

    More updates real soon!

    Rich
     
  15. DexJay

    DexJay Member

    Trophy Points:
    191
    With the buck really looking to be getting somewhere it was time to fine tune the moulding line at the rear, greeblie indents and other details.

    View attachment 110687

    The rear (spoiler) flip-up section needed some work, getting it symmetrical and getting the curve like it should be in reference pics.

    View attachment 110688

    The hole for the top Molex connector is being roughed out for position in this photo and the grade of paper is getting ever finer.

    View attachment 110689

    At this stage the Yamaha engine cover and disc section is being worked with a piece of MDF on the inside and a blending of the chamfer. Trial fitting the buttons/catches too and they seem about right.

    View attachment 110690

    By this point the big work is almost done! Just a case of getting picky and adding another coat of primer

    View attachment 110691

    Offered up on a dummy head suggests the scale is close. The Y-wing helmet is a large lid, but still only about the size of an X-Wing one...

    Until next update which is more primer & Wet n Dry time!

    Rich
     
  16. DexJay

    DexJay Member

    Trophy Points:
    191
    Hi again,
    With the lid all near ready for more primer after the cellulose primer it was time for some 2K Automotive paint. Nasty, but rather that spray it and put it in the air you can get away with applying with a roller.

    View attachment 122650
    View attachment 122651
    After 2-3 coats you need to let it harden - wet and dry with 1200 and 2000 and reprime in areas you may have rubbed through. So with some luck you'll have something that resembles this -

    View attachment 122652

    After a good polish I made a box to place the lower half in and made a crude cardboard template, followed by one in MDF.

    View attachment 122653
    View attachment 122654

    Almost ready for casting now! With a trusty glue gun and yet more cardboard it was time to shutter it all up - after all you don't want the Silicone everywhere!

    View attachment 122655
    Until next time!

    Rich
     
  17. Artman27

    Artman27 New Member

    Trophy Points:
    2
    Awesome! totally awesome! Can't wait to see the finished product.
     
  18. DexJay

    DexJay Member

    Trophy Points:
    191
    Thankyou Artman!

    With the buck all ready to go I mixed up the Silicone for the 1st pour with no thixotropic.
    View attachment 125334

    ...add a 2nd... and a third pour...
    View attachment 125335

    ..then a touch of thixotropic for a 4th pour.
    View attachment 125336

    I made some locating blocks (that were a little too big really) and added those after the 5th pour.
    View attachment 125337

    Then a 2 piece (to make 4 in all) fibreglass mother mould that would bolt together all the way round.
    View attachment 125338

    (Missing are the repeated steps for the other side, making sure to add a Silicone release agent to stop the 2 silicone sides sticking together!)

    Although I wasn't going to slush cast this I figured I'd leave it open as a possibility if the GRP didn't go well!
    View attachment 125340

    ..and there it was, ready for action!
    View attachment 125341

    Thanks to Nate (Heatshock) for his email support!

    Next time, gelcoat!
    Rich
     
  19. DarthVader1

    DarthVader1 Well-Known Member

    Trophy Points:
    716
    Good Lord. That's such a beautiful cast and progress!
     
  20. practicecactus

    practicecactus Active Member

    Trophy Points:
    391
    Oh wow. From the first set of pics I could tell this was gonna be good. Looks like it's gonna be a * fine helmet. Nice work.
     
  21. DexJay

    DexJay Member

    Trophy Points:
    191
    Hi, thanks for the kind words guys!
    I've not got around to updating the build in a long time, I started a build diary over on thedentedhelmet initially you see!

    I'll get busy and get some more pictures uploaded and text shortly!

    Rich
     
  22. DexJay

    DexJay Member

    Trophy Points:
    191
    Right, more pics!

    B1.jpg
    With the white gelcoat done a few hours before it was time to start with gel and matting. Here's the halves with a first coat..

    B2.jpg
    ..and a second coat of resin and matt. I over built this one as I went for a 3rd layer too! Subsequent ones just were 2 layers.

    B3.jpg
    Once a few days had passed (to be safe) I popped them out of the moulds to see how it went.

    B4.jpg
    Yep, quite pleased actually! They look quite promising!

    B5.jpg
    These were always going to be produced in 2 halves due to the awkward returns here and there. With the halves aligned temporarily with tape I started to bond the 2 together with Mastic. Starting at the middle and working forwards and backwards.

    B6.jpg
    Once the Mastic had cured (and before the final tissue coat of fibreglass) it was time to roughly cut the opening. Taking my time with a drill and small bit before cutting through the holes.

    B7.jpg
    With the centre section gone the opening was trimmed more evenly to tidy things up.

    B8.jpg
    Here is a picture for comparison of size of Helmet Number 2 in the capable hands of a friend in Germany who was kind enough to make a set of greeblies for me. Its alongside a Signature Edition replica of Luke's X-Wing helmet and I don't think I'm too far out.
    The goggles in this pic have yet to be made at this point, but I'll cover that shortly!

    I'm pretty pleased as this is my first helmet, first scratch build and first time I've used Silicone! Until next update!

    Rich
     
    johnojodo likes this.
  23. mr paul

    mr paul New Member

    Trophy Points:
    2
    Hi Dexjay. are you still making these Y wing helmets. i am looking to get my hands on one and O cannot find any as good as yours. Thank you for your time.
     

Share This Page