I've decided to split the Vader project into two helmets...the clay sculpt, and the specific Kid Vader helmet already casted.
So I've stripped the Kid Vader helmet used at Oz Comic Con and am going to resand it to smooth the helmet, and fix a couple of areas of the mask with bondo and clay.
I will now take molds from both...the clay sculpt will form the basis of the adult tailored ANH helmet, with that Kid Vader cast modded into an ESB version that is tailored a little more for a child. Although both are wearable between adults/kids, I will incorporate a couple of more kid friendly tweaks in the Kid-Vader ESB than in the full version:
Kid Vader ESB helmet will be a little shorter than the full version; I've found from experience that this allows smaller wearers to move it around on their head easier and reduce the chance of it hitting shoulders, as well as to save a little weight.
Kid Vader will have a shorter neck, again to allow smaller wearers to see reasonably well throught the lenses. I will reshape the neckline however.
Kid Vader ESB will have the larger chin vent cut-out to help with ventilation and visibility. The mouth and grill is a rubber diamond-shaped mesh that I've fortunately found in a garden hardware store! I'm really happy with this find as it's accurate enough in terms of shape and size. A little kid-friendlier than the metal car air filter mesh I will seek to use in the adult helmet.
Kid Vader will have the top-mounted helmet attachment assembly as seen on the screen helmets from the get-go; the ANH sculpt will remain with a velcro attachment on the forhead with side padding within the helmet for now.
Kid Vader's helmet will sit a little different than the ANH version, i.e. a little higher over the brow etc, but I'm sure you guys all know that.
At the moment, the Kid Vader nose bridge is a little narrow, I have been thinking to leave as is in order to get a little more lens area for visibility, but I may decide to just widen it a bit anyway coz the inaccuracy of the narrow nose bridge irks me.
The quick one-off helmet cast I did also better matches the ESB helmet as the nose bridge doesn't end in a 'point' like the ANH helmet.
The sculpt will remain ANH at first, but I still plan to then mod the sculpt for ESB/ROTJ. Here's both together, the ANH sculpt to the left, and Kid Vader ESB to the right...I am also building a return edge into the Kid Vader helmet as well. I am now thinking of runs for both, preferably as unpainted kits because I don't regard myself great at painting.
Kid Vader profile now that it sits like ESB...
Helmet will stay a little shorter than the full version I am also sculpting at the moment, it helps with smaller wearers for both weight, and to reduce it sitting directly on shoulders...
Front, with return edges being added, larger chin vent cutout, but narrow nose bridge...I think I'll widen it with clay before taking the mold. The mask's left cheek also needs a lottle bondo along the top, just to make that curve a little more subtle. The neck to me, is a little wide on the mask's left side, but I'll keep it that way to keep it a bit more open at the bottom for kids, I'll just reshape the neck line curve a little though...
Meanwhile, I am doing some final tidy up and adjustment to the ANH clay sculpt, ready to order the silicone for molding...that neck is a real challenge to get right, it seems to be different from one photo reference to the next!
The way I make the lenses at the moment is to simply save the clear plastic packaging around big easter eggs, cut the curved lens from that, then hot glue some mesh behind it. That way, you get yourself a giant easter egg and vader lenses!