Need help: Adjustable helmet attachments

[burgerstrings]

Hey guys, I'm doing a Megaman/Protoman costume(s) for an upcoming film and i hit a bit of a snag with the helmet. As you see in the picture there are two mandible cheek protector things. yes they look cool, but they inhibit the actor from putting it on. I still have to mold it and trim it up when i cast it, but i need a way of either detaching/re-attaching the things or having them be hinged on the piece. If you guys have any ideas i would be extremely grateful. Filming doesn't start til end of October so i have a little bit of time.
Thanks again

 

[PrimoOptimoso]

I'd almost think that means the helmet is too small. I'm about to do a MM helmet myself (just a one-off buildup, not a mold and cast) and one vibe I get is it's supposed to be like the size of a motorcycle helmet: pretty big. With a motorcycle helmet, if you took away all the protective padding inside the lower crossmember under the visor, there would be plenty of space between face and shell.

I assume by the shell you posted that it's getting a bit more of a realistic look, so discount the cartoon proportions if you like, but I would keep the moto helmet thing in mind at least.

 

[burgerstrings]

Well, the helmet was originally too small to the point that it fit, but very snug. That was before i added the cheek guards and such. We're trying to keep it realistic so a motorcycle-sized helmet is no good. Like i said, it fits, but the cheek guards need to be removed to put on then attached afterwards to create a very fitting piece.
Thanks

 

[PrimoOptimoso]

Well, if that's the size you want, then perhaps you could do this:
- cut the mandibles off at the circular edge along the ear pods and the edge between the indent and the flat top surface of the mandible (just the two cuts and it should be fully separated if you know what I am getting at)
- Cut a slot in the forward arc of the circular ear pods
- Extend a flap rearward along the inside surface of the mandible to fit in the ear pod slot
- Extend a flap downward from the cut, indented edge (seen above the mandible piece) that will be a layer behind the mandible when in place.

That way, you can slot in the mandible at the ear pod, and velcro or double-stick-tape the inner surface of the mandible to the new sub-layer coming down behind it (whichever will hold for filming) - with a tight enough tolerance on the slot, you wouldn't have a gap at the ear pod and it would look the same. at the top surface of the mandible, if that's got a gap, maybe use an adhesive or something that can be just cut away with a razor for removal between scenes. Not perfect, but might work.

Alternately cast it in a very firm rubber so it'll flex for the actor but retains its shape easily and durably.

 

[burgerstrings]

Thanks Primo. Your idea for the clip with velcro sounds ideal. You sound like you have a fair share of experience with this kind of stuff.

 

[PrimoOptimoso]

Ha, youre too kind. Actually it comes from far too many 'aw crap' moments where i have had to dismantle things because i forgot a piece or step, etc.

 

[aron42486]

I ran into the same concept problem when designing my X helmet. You are just gonna have to find an edge or seam to cut the mandable off at. Some edge you wouldn't notice it on and use magnets or something to reattach.

I wouldn't bother with a hinge, it will be more of a pain than it's worth.

You might be able to only cut one mandable off to give you space. No need to do both if you can get away with only doing one. If you add in seam details all over the helmet to make it look like it is made of metal plates instead of one solid piece it might help hide any cuts you have made.

Whenever I build my X helmet I will probably be adding these kinds of details to it.

I would recommend keeping your fix as simple as possible.

 

[PrimoOptimoso]

I wouldn't bother with a hinge, it will be more of a pain than it's worth.

Hinge? No hinges here for sure.

You might be able to only cut one mandable off to give you space. No need to do both if you can get away with only doing one. If you add in seam details all over the helmet to make it look like it is made of metal plates instead of one solid piece it might help hide any cuts you have made.

Quoted for truth and good points.

Here's what I was talking about.