Doctor Who Yellow Space Helmet

[sbeall]

Fantastic! You’ve done great on this project. Your attention to the details and shapes of your 3D prints is truly top shelf.
Someday I’ll build my own. ( Nowhere near as nice as yours.) I actually just missed an auction for the base helmet. They all sold before I could place an order. Looks like I keep hunting.
Enjoy your Con!

 

[Engineermaker]

Thank you Sbeall.

Also I think I can help you find the parts...

 

[Engineermaker]

The helmet held up well at Comicon Stockholm this weekend. Not even scuffs and scrapes even though I hadn't had time for any laquer for the paint.
People say 3D print props are brittle but the solid print ABS seems actually fairly sturdy. Some small parts would shatter if I dropped the helmet so these I aim to make spares of to bring along to cons.

The air system is flawless, well I forgot to charge the big 8 hour battery for day 3 so I quick charged it on site and still got half a con day out of it.
I'll say this about the Scott Tornado respirator system, it's really good. I have both the simpler variant from before and now the black one with power and charge led indicators and alarm. When you learn how it works it's pretty great.
Before using it I attach the tester that comes with it to indicate safe airflow. It's pretty great, gives a physical indication and gives confidence in the resoirator.

When you build the helmet you will need the tornado respirator, it's an airtight helmet with a minute worth of air inside so you need the professional airflow system to wear it for any lengt of time.

All the wiring I put in the helmet is standard sections of 12v extension and fork cables using 5.5 / 2.1 mm connectors so they are glitch free (most other small and handy plugs aren't) and easily replaced.

One thing I want to fix is I just taped the wiring to the roof of the helmet from lack of time before the Con and I want to replace the tape with stripe points or even better velcro points.
I could add these to existing screw & nut points, I'll figure something out with that.

I also need a velcro strap to hold the 9v pack and lights dimmer.

 

[sbeall]

Well, I’ve done it. A little spontaneously, but a good deal came along on the welding helmet.

I’ve just got to clear some projects off the bench, find some time, and figure out how I’ll build the parts. Easy, right?
(What have I done? )

 

[Engineermaker]

Sbeall, this is great!

What have you done? What have I done leading others down this path!
At least you don't need to put all the hundreds of 3D modeling hours into it. I spent the greater part of 3 summer vacations to get the bulk of it done.

But don't worry, you can do it.
The payoff when you can hug your finished space helmet like I did and then the joy of showing it off to friends is priceless.

I actually decided to upload all the stl files I have now to Thingeverse or eqivalent service.
I can update them over time and re-release if needed later. I'll start looking over my files this weekend.
Probably... Home sick with the flu now so I can't concentrate to do it now, no energy.

Since I use insert blocks that need sanding smooth and use real screws and rivets as well as drill and tap some holes manually it's some DIY work to assemble. But it's not too complicated. Lining up holes on the helmet and adjusting the lighthouse to be straight was the hardest part, I just did it by eye but you can use measuring tape and mark it up to make it easier.

If the block system is getting too hard to use I can merge it all in my cad system and only have a couple parts as inserts. Won't look as good finished but it'd make it far easier. But give it a try.
You could start with the sub blocks for the ear pieces like I did to get the hang of how it works. Most pieces are pressed in place in slots, some are screwed in place.

 

[sbeall]

EngineerMaker you are my new hero. If you can share your files on Thingiverse I’ll probably be the first one to download and print them. I have no skill in 3D modeling, and I wasn’t looking forward to learning on a project of this complexity. My only successful design/print attempt was a cylinder with a hole in it, and it still took 4 tries to get right.

Don’t blame yourself for leading others over the edge. It was always there, in our genetic heritage...

The urge to jump?

This is a piece I would have made sooner or later, whether it was made of styrene and foam, or I learned how to vacuum form, I don’t know. I have no problem with finishing prints, or adding real screws and things. And in my estimation several smaller prints are easier than one large print, and the price of failure is reduced, too.

Anyway, I really appreciate the help. I’ll update with progress, or even start my own thread one day!
Geronimo!

 

[Engineermaker]

Sbeall, it's my pleasure.

We need more orange spacesuits out there, isn't it time after what, 12 years from when it appeared on Doctor Who to get a decently screen accurate helmet build available?

I'm sewing a new spacesuit for my cosplay from Cordura when I find the time and need to make a modified pattern from my old one (longer neck and a little looser fit mostly) so if you need a pattern I may have that too given time.


By the way, you need the tornado respirator, battery and charger to wear the helmet for more than a minute...

 

[sbeall]

By the way, you need the tornado respirator, battery and charger to wear the helmet for more than a minute...

I know, I had to try it on If I decide to do any cosplay with the helmet, I will definitely get the powered respirator. Right now I’m concentrating on just the helmet.

This helmet is very under-represented. I’ve only stumbled on a handful of recreations. Yours is the most exacting and screen accurate. I think this the best (and certainly my favorite) space helmet from recent television. I’m still trying to put my finger on exactly why.

 

[Engineermaker]

It feels like a real thing when you put ut on.
It's comfortable enough to wear for hours, so actors could really relate to being in an enclosed and practical system and it shows in their performances and body language.
This is probably why.

You see the same thing with the M3 respirator based helmets used in Expanse.
I'd like to make one of those too actually.
Expanse space helmets are either M3 respirator helmets for the Rozinante crew, high altitude parachute helmets for Martian commandos or the Belter suits that mostly use legacy soviet high altitude bomber helmets with some modifications.

There's the power armor also, I think those helmets are all original to the series and as a result look the least practical work equipment-like.

 

[sbeall]

Good evening, EngineerMaker. Just wondering if you had made any progress on uploading your files to Thingiverse.
I have to admit I haven’t started on The Expanse yet. I had to look up some images. Those are some badass space suits.
Anyway, looking forward to getting a start on this project!
-Seth

 

[Engineermaker]

Sorry I'll put more effort into getting this done.
Hopefully I'll have the first files up this weekend.

 

[Engineermaker]

Both Thingeverse and Myminifactoyr are real slow giving me access right now.
Perhaps I have better luck tomorrow.

 

[Engineermaker]

Done! Here's the link to download the entire project.

Enjoy.

3D Printable Doctor Who Orange Space suit helmet build by Johan Gemvik

This is a set of models to print and mount on a Scott Procap Welding Helmet to make the Orange spacesuit helmet from modern Doctor Who.The helmet was used by 3 consecutive Doctors spanning from David Tennat in 2006 who used it figting a huge Demon at Sanctuary Base 6, then in several episodes by...

www.myminifactory.com

 

[sbeall]

Wow. Amazing. I can’t thank you enough for all the great design work you’ve put into this project.
It may take a little time, but I’ll keep you posted as I work on this.

 

[JKRIB]

Wow. Amazing work on the helmet!

I have the white ProCap helmet but the modifications are very daunting!


I have all the other parts:
Cosplay suit
SB6 patches
Extremities Gloves
Black Diamond Harness
Straps + Buckles
Salomon F20 Boots

I put the boots and gloves in The Junkyard section.. but having second thoughts

 

[Engineermaker]

Hi JKRIB,
the 3d printed parts mounting was easy. The hole for the moved hose connector and addition of the bellows are a little complicated. But not that much. The plastic of the helmet lends itself well to drilling (not brittle) and I drilled corners then used a woodcarving knife to carefully enlarge the hole for the moved connector.

For the wiring I just used pre-made wires with connectors you plug in and glue or tape to the roof of the helmet.

None of it is all that demanding compared to some prop builds.

I suggest printing the parts, getting the screws and nuts (I'll post a list here), place the printed parts with dual sided tape for a mockup and then figure out the rest.

I'll be happy to give more detailed help as you go along.
As I was thinking of re-fastening the wiring and repair a broken printed part I could disassemble and re-assemble the helmet and make a video of how to mount parts.

Or maybe make instructions with photos. That might be even better...

 

[sbeall]

JKRIB, don’t worry. There’s plenty of support here. I know there a lot of parts to this build, but take it one at a time. Also, you were smart and got the white helmet. That should be much easier to paint than the black one I snagged.
Once I start printing and building, too, I’ll share progress reports, and we can help each other out!

 

[HenryTheNerd]

It's in quite a few but it was in "Kill the Moon".

Also the impossible planet if I'm not mistaken

 

[JKRIB]

Orange space suit appearances:

10th Doctor:
The Impossible Planet
The Satan Pit
The Waters of Mars

11th Doctor:
Hide

12th Doctor:
Kill The Moon
The Girl Who Died
Listen

Am I missing any?

Also, I sold those gloves and SB6 patches and kind of regret it
Maybe I just need to make this space suit, after all !

Here are some photos of the production helmet from Mark Cordory, who worked on the props.

 

[Engineermaker]

Orange space suit appearances:
....

Am I missing any?

Also, I sold those gloves and SB6 patches and kind of regret it
Maybe I just need to make this space suit, after all !

Here are some photos of the production helmet from Mark Cordory, who worked on the props.
...

Thank you for the list and excellent photos!
I think you can still find the gloves on ebay.
"Extremities Ice Gauntlets"
The Arctic boots are still being sold, so is the old version climbing harness. Well they used the newer version too (clara has the padded belt version in kill the moon)

I think the list is complete.
The same procap base helmet was used with the welding visor on in one ep also (if I recall correctly) but used for a different build, and a variant for the orange suit was used for diving gear.
But for the real orange space suit I think the list is complete.

The photos show things I didn't have clear images of. I think it's time I updated the models to get these details right.

Mostly it's the chin light and the bent sparkplug thingee at the back bottom of the ear piece. I see it's also the connector ring for the ribbed hose going into the back of the lantern housing. That last one just takes a minute to update.
The rest take longer. I've been meaning to do these updates but seeing clearer photos help to understand the sometimes mysterious geometries better.
Especially that top view.

I'll do these changes and upload on Tinkercad given a bit of time.