Don, the helmet you see in my signature line came from that mold of the screen-used ANH helmet (that helmet is the one that Kermit wore during the ANH promotions and was documented at Don Post studios). The previous owner of my helmet told me that the mold you refer to may have been made by Rick during the pickups of ANH. Is that something you heard anything about? But I think it is cool that you actually used that mold as well for your own Vader project.
What do you mean by re-worked for ESB? Just that the chin vent was cut out a bit and a mounting ring added? Because otherwise the ESB masks are nearly identical to ANH. The helmet (dome) was modified very slightly.
So what was the condition of that ANH helmet mold when you got to it? Do you think it is still in the archives? That would be very interesting if it indeed was the source for the ROTJ masks/helmets, thereby discounting the idea that the ROTJ helmets were just reused ESB helmets.
I'll point out that the ESB masks at least do not come from that same ANH mold you refer to, but rather another mold or casting they had in the UK at the time. There are a number of reasons why this is apparent but you'll recall the ANH mold you used didn't have mounting tabs on the top of the mask, whereas the masks created for ESB did. Both came from the original ANH mask (or the whole helmet) but it was molded more than once.
I'll leave it to the experts to discuss the differences, because I never looked at it as closely as some of you. However, IMHO, the ESB mask--and particularly helmet--look much "cleaner" then the ANH versions (no disrespect for Mr. Muir, who I think did a fabulous job). It seems apparent that they took a casting off the ANH, possibly in plaster, and smoothed it out here and there..at least that's what I would've done. Again, there's no doubt that a new mold was made, as the ESB Vader has its mount molded in, whereas the ANH model doesn't have anything on top. Also, the mask used for the Vader reveal in ROJ has the mount "crown" in it's casting as well. I'd be surprised if they made yet another mold/set for ROJ...However, I have been wrong...
I am getting confused with all this talk about this type and that type, so I hereby set forth a new naming convention based on the four versions I'm aware of:
ANH (has a little clippy-thing that holds the helmet on, sculpted by Brian Muir)
ESB/ROJ (re-molded with the Ring Mount inclusive, and Velcro on the forehead to help hold the helmet down)
ILM APPEARANCE (The ones in the photos in this thread, with a tall Ring mount and forehead Velcro)
1995 APPEARANCE (Similar to the above)
That's all that reside in the archive, folks. The only"stunt" variation I'm aware of is the one with the see-through cheeks and chin that Bob Anderson wore--and still resides in the Archives.
The ANH Vader is in the same condition in the archives now as it was when I started there...somewhat beat up, and doesn't look like it was ever restored, unlike some of the other masks.
--Don Bies