My Early Disasters pt 2 - A Biker Scout Helmet - How hard can it be?

So, it's been a long time since I posted. As usual, it's because of life getting in the way of hobbies. I was enjoying the speeder build, but it turns out, a thing on that scale isn't the kind of project you can dip in and out of, especially if it's a vanity project, rather than a family thing.
I got the build so far, but the next steps always took more time than I had available. The bike sat in the basement, being shunted around from place to place as I tried to find the time, but eventually I had to admit I wasn't going to get that.

So, I've dismantled the bike. The process taught me a lot, and I'm proud that I did measuring and planning this time. And for the first time is YEARS I have no idea what to do next, or when to do it. I want a small project again, after the dalek and the bike. Whatever it is, you lot'll be the first to know.
 

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I found a car air freshener in the supermarket. It's a model hockey helmet in the colours of the Canucks. It's not that big.
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I mounted it on a small post to modify it, first removing the face cage thing.
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I'm using Plasticine to do the modelling, not clay.
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Hoping that I can do this in stages - the plasticine will not dry out, so I can leave it for extended periods. When I'm done, it should be firm enough for me to try making a mould from it and casting it in resin. I've gone from a project so big it got int he way of doing the laundry, to a project so small that Mrs Dim hasn't noticed it at all....
 

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Yeah, so I chickened out of the tiny helmet game - I'm not good at details at the best of times, and don't seem to have the fine motor skills for a tiny sculpture. Thus I went back to scratch building a Mando bucket. I thought I had measured carefully, using my old Stormtrooper build as a guide, since it's pretty much the only helmet Ive built that fits my head. However, something went awry (as usual) and I have this enormous thing instead. I worked pretty hard on it, and it could be tidied up to look quite shiny, but it's way too big. Then I happened across this:
I'd bought some new flooring mats in preparation for the February Fan Expo (the kids always need SOMETHING built). I followed the link under the video, and they DO have free Mando bucket plans. I also liked the tip about using the bandsaw to cut the foam (my blades are shot anyway, thanks to last year's vinyl floor tile fiasco...)
So..
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I have a day off coming up, and reckon I can finish the left hand side of the helmet. Then it's a question of making the right side even roughly match, and surfacing etc etc. Thing is,
building just this much only took an hour or so. Oh, but I'm gonna need some visor material. Anyone got any suggestions? (Aside from "Get a different hobby!")
 

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Hey Damien,

These are being used by lots of people for Mando facemask shields:- Sellstrom S35020 Replacement Shade 3 IR Visor for 390 Series Face Shields - Uncoated (from Amazon)

Roughneckone:cool:
 
It's taken a VERY long time, but I finally have the right hand side fitted. The tape is to hold it in place until the foam sets. Or doesn't.
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I've been at this for years. Maybe a few fewer years than it feels like, but quite a while. And I don't often learn from my mistakes. But here's the latest helmet, a foam base cut using tools and instructions, and fitting together pretty well. What's more, I haven't just glued in the last piece and called it good enough for paint, I'm adding Bondo. AND, after adding the bondo, I'm sanding it nearly all the way down to prepare for another layer of bondo.
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Weird. I don't even know me anymore....
 
Still going slowly. Sand, sand, sand, spray, curse, fill, sand, sand, sand.....
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Made the rear grill thingy out of card and then sprayed it. Gonna wait and see whether I have to sink it into the back of the helmet or just stick it on.
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Ok, it's been almost two months since I last updated. Dunno if anyone's noticed, but life has been a little unusual during that time. Theoretically, having more time at home (laid off until next week) meant more time for helmets, but it turned out Mrs Dim had a Pandemic plan that basically included repainting or rebuilding most of the house. Oh, and she had a bad back, so I had to do the actual work bit.
Anyway, whinging aside, I DID finish up the Mando helmet, but have a couple of things to admit:
One, as usual, my measuring was wrong, wrong, wrong, so the crest does not run evenly front to back.
Two, as usual, my surfacing was terrible, something that shows up even more than usual with the silver paint.
Three, I should have noticed from the instructional video that this helmet is too short for the width. The actual Mando helmet is longer, so this one looks....wrong.
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Never one to let abject failure slow me down, I watched the final season of "Clone Wars" on our pandemic-purchased Disney +, and got a hankering for a clone helmet again. This time it was Hunter, from the Bad Batch.
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I think it's a basic series 2 clone trooper helmet with a nifty paint job, but I could be wrong. I wanted to do this build differently, since every attempt I have made up to this point has come out badly (or at least, not as well as I'd hoped.) With most helmets it's the surfacing on the dome that's the issue, so I figured I'd make that and keep it separate for as long as possible. That way I could sand and smooth and put in the details without worrying about the rest of the helmet.
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I started with an oval of foam with the right length and width measurements, and used cardboard to make the vertical pieces. I built a lattice from cardboard strips, then coated the whole thing in tissue-paper mache. I was going to bondo next, but only got half coated before my bondo ran out.
I thought I might build the lower part of the helmet Atlanthia-style, with cardboard delinating the shape and then mache over the top, like I did for the Stormtrooper build all those years ago. Instead, though, I made another oval the same dimensions and curved the back of the helmet around that to the point where the "ears" stop.
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Oh, and by the way, I'm working from some very nice reference pictures which I had found and printed off. It just worked out that the main ref pic was 1cm to 1inch in real life, which means I can actually measure some parts for real! Lucky break! Although, obviously, sometimes I look at the measurement, convert and say "Huh, that's gotta be wrong" and guesstimate instead. Bodging is a hard habit to break.
Here comes the bit I'm proudest of: I measured and drew out half the faceplate. Then I drew it onto foam, flipped it and drew the other half. A symmetrical faceplate that ACTUALLY FITTED FIRST GO! No filling in!
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My other great find was that I could glue the edges of the foam and then hold them in place by pushing finishing nails into the foam like pins. They hold really well, but are easy to remove. Next I cut the cheeks, shaved the edge and glued them in on the right(ish) angle.
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What's nice about this version of the helmet, is that the ridge around the neck is flat, not semi-circular. I could just make a band of foam that ran around the back and came to the ends of the ears. The next section is also a box rather than a tube, so it was fairly easy construction.
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By this point, I had accumulated a bunch of small gaps and rough edges (not changing scalpel blades often enough. Budget.) I grabbed the tissue paper again and mache'd the whole assembly. This helped with the cheek joins, as well as looking strangely reminiscent of the animated helmet - there'd been some black paint in the glue I was using, which tinted the white tissue paper.
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I have to say, even if I went no further, I was pretty blown away. Usually by this point I am already disappointed. Here, there's only the dome that's not great, and I'm planning to take more time with that. I need more bondo, realistically, and even if I decide to shortcut and use filler, I'm gonna surface with resin (of which I have quite a bit stockpiled.)
I can't make the bottom half of the faceplate until I have the two tubes either side of the vocoder in place. My measurements indicated about 3.5 to 4 inches, which looked silly, so I went with 3 inches.
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That was this morning. Like I said, I got reactivated to come back into work next week, so I suspect I'll give a little more time to this helmet in the next couple of days than I should, but I don't want to rush it. When I get the next bit of faceplate put in, I'll mache again, then coat the dry mache with resin for strength. If I do get around to bondoing over the top of this, I'll want to keep it as thin a layer as possible. Am I learning? Is this what learning feels like?
 
I went to work on the lower part of the faceplate, but something went awry. It was way too big, in pretty much every dimension:
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However, I'd been measuring, and I didn't want to start cutting and adjusting by eye just because it looked a little weird. I mean, it might just be the colour, right? So I trimmed down the ends of the tubes, and set to putting in the vocoder bit.
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Putting in the background for the vocoder didn't help a lot. I know it's supposed to be a small curved piece that links the two tubes. This is way too wide. Then I tried the helmet on, and that proved the bottom half stuck out too far:
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Putting in the three vocoder vanes just made the whole thing look goofy.
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Like a duck with teeth.
So I measured again, and this time it looks like the lower piece is a whole inch too long. I had to trim back the edge, then re-set the vocoder piece. I also cut into the sides to bring the tubes in a little, angled instead of parallel.
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There's something still a little off about the curve of the lower faceplate, and the angle of the right side tube (as we're looking at the helmet), but the proportions seem better now. I sprayed it all black to remove the clash of colours.
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It feels like this build is going better. For one thing, the dome is a separate issue, and one I feel I can relax about for now. The rest of the build is going well because I have some good ref pics, and I'm measuring fairly consistently. I may not be spot on, but the parts are a similar scale relative to each other, so I won't get a tall and thin monstrosity like the Death Trooper helmet was. I hope.
May pick up some bondo this weekend, and Mrs Dim has muttered that it may be ok for me to buy her friend's reconditioned 3d printer! Imagine the mess I can make with one of those!
 
It looks great from the side....
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But I'm going to have to do more work on the lower front piece and the dome. Didn't get the bondo yesterday, and now I'm back at work, so things are going to slow down again. No word on the 3d printer yet either. Bother.
 
Twice now I've cut into the lower faceplate and moved the front ends of the tubes further in. I think it's better, but still not right. The dome is a horror show that might get better with bondo (like THAT ever works!)
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What's really bugging me right now is that, compared to the ref photo, it looks too tall and thin. I'm thinking I'll widen and deepen the eyeslit to compensate. (Don't spend too long re-reading that sentence, it won't make any more sense.)
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In other news, I picked up my 3d printer today. After a couple of false starts, I got the hang of importing files, converting them and printing them off. Now I need to invest in more PLA (This printer, the Flash Forge Finder, is PLA only) and consider whether I want to try 3d printing a whole helmet. Part of me says "Sure, why not? There's still a buttload of sanding and gluing before you get something to put on your head, right? It's not THAT different." And part of me says that I'll just be putting together something someone else made. Another part of me is saying this diet is stupid and I should buy beer, and there's still that other part that insists an anti-gravity generator is a viable project if I just give it time.... I have a horrible feeling my 3d printer will simply be an expensive way to make action figures for a while....
 
I had a breakthrough. It's my day off, so naturally I was looking for ways to avoid doing household stuff. While hiding the lawnmower in the shed, I found my old bike helmet, and realised it was exactly the right shape for the dome - wide, shallow, and with a steeply-sloped back. It turned out it wasn't long enough for the helmet, which strongly suggests the helmet is wrong, but we knew THAT, right?
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Being a logical type, I cut it in half, attached the front and back bits to the helmet and temporarily filled the gap with duct tape. Don't look at me like that, I said it was temporary. Then I put the whole thing on my head to confirm I still look stupid wearing it....
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That done, I trimmed the eyeslit a little to try and balance the whole "Tall and thin" thing. Might work. Anyway, the next phase is mache again to smooth over the rough spots, then bondo over the whole thing to make it look a little hardier. Today I also used the 3d printer to print an Imperial Belt buckle, as a precursor to my long-awaited (by me) Director Krennic outfit. Anyone got measurements for Imperial Rank Badges?
 
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