Rebel Endor Helmet Build

[Halliwax]

Wicked nice work

 

[Mottrex]

And if you ever wanted even more proof Mottrex, you can see in this screenshot, when Luke pulls of his helmet, the cap falls back, but he is holding the brim. If it were attached, you wouldn't see daylight through it. This blew my mind when I realized it, but the auction prop photos sealed it.

That's an Amazing Proof shot!

 

[TheDragon]

From my research (and making a few of these things) the brim is covered in two pieces of fabric - kinda constructed like a regular baseball cap brim (to paint a bit of a word-picture). The ribbed part, and rear "skirt" piece that only Luke and Leia's helmets have, are attached to the AN-H-15 cap... with specific note to the ribbed section being either tack-stitched or glued down, because in the location shots they're pretty well pressed down onto the cap, and once they're back in the studio filming the speeder bike chase shots the edges of the ribs are popping off of the flight cap.

My guess - based on the last one I worked on - is the skirt and the front edge of the ribs are machine stitched to the flight cap, and the bias-tapped sides of the ribs are glued or tack stitched. Either way, that part isn't attached to the donut and brim.

Yes, from what I understand from closely looking at the DICE 3D scan of the helmet, the brim is two pieces of fabric stitched at the edge of the brim and the leather ear covers are attached as below. I've made templates directly from the scan for both of those parts and working on the ribbed portion but can't figure out how it was attached (the 3D model obviously doesn't show the inside of the helmet), as well as this it's missing the "skirt" you speak of as its of a background helmet not a Hero.

I'll admit this project has been on the backburner for the past few months as I've been working on another helmet. Very keen to get back into it within the next few months though.

Hopefully RS can hurry up with their replica and figure out the missing pieces of the puzzle for me lol.

 

[DJb1138]

Yes, from what I understand from closely looking at the DICE 3D scan of the helmet, the brim is two pieces of fabric stitched at the edge of the brim and the leather ear covers are attached as below. I've made templates directly from the scan for both of those parts and working on the ribbed portion but can't figure out how it was attached (the 3D model obviously doesn't show the inside of the helmet), as well as this it's missing the "skirt" you speak of as its of a background helmet not a Hero.

View attachment 1927971


I'll admit this project has been on the backburner for the past few months as I've been working on another helmet. Very keen to get back into it within the next few months though.

Hopefully RS can hurry up with their replica and figure out the missing pieces of the puzzle for me lol.

What're some of the missing pieces for you, man?

 

[TheDragon]

What're some of the missing pieces for you, man?

So far I have accurate data for:

• Main Vacuum formed "Halo"
• Brim cloth element
• Leather flightcap additions
• Ribbed cloth element (outside the helmet)

What I still don't know for certain (or have data to backup my assumptions):

• Ribbed cloth portion (inside the helmet)
• Paint*
• Open cell foam (inside the helmet)

In regards to paint, I have no way in knowing the colours I have are correct or if they're too drab.

 

[DJb1138]

So far I have accurate data for:

• Main Vacuum formed "Halo"
• Brim cloth element
• Leather flightcap additions
• Ribbed cloth element (outside the helmet)

What I still don't know for certain (or have data to backup my assumptions):

• Ribbed cloth portion (inside the helmet)
• Paint*
• Open cell foam (inside the helmet)

In regards to paint, I have no way in knowing the colours I have are correct or if they're too drab.

Gotcha. I could tell you that, with a decent degree of certainty, that the ribbed portion is not inside the flight cap at all - it's definitely on top. The construction was a bit of a pain at first, but is kinda like the X-wing flak vest's ribs (if you can imagine how that's put together) just far closer together.

As far as the paint is concerned... they probably used Floquil (the ILM shop used a ton of that stuff). I can't imagine they used super vibrant greens on it, as it's got a military vibe going, but I think the color you landed on works really well.

The open-cell foam... I bet that can be found on Amazon or something. My guess is it was used to maybe stabilize the form a bit and add a larger friction point to keep the donut on the flight cap.

** A note about items like the flight caps and other "found" military props from the era is that, more than likely, LFL/ILM kept a few in the archives, but most of them were sent back to whatever armorers/suppliers in the area provided them to the production. That way they could be stripped and reused for other films.

 

[DJb1138]

this is the rear "skirt" I was referring to:

 

[DJb1138]

So far I have accurate data for:

• Main Vacuum formed "Halo"
• Brim cloth element
• Leather flightcap additions
• Ribbed cloth element (outside the helmet)

What I still don't know for certain (or have data to backup my assumptions):

• Ribbed cloth portion (inside the helmet)
• Paint*
• Open cell foam (inside the helmet)

In regards to paint, I have no way in knowing the colours I have are correct or if they're too drab.

I meant to ask before (and totally thought of it again now, haha) - what've you come up with for the leather "chin flaps" added on? Have you sorted out the weight of the leather as well as the color?

 

[TheDragon]

I meant to ask before (and totally thought of it again now, haha) - what've you come up with for the leather "chin flaps" added on? Have you sorted out the weight of the leather as well as the color?

I haven't gotten to the colour or weight, only put together a quick template off of the scan data, I'll be buying leather soon for another project so I'll do some more digging then.

For the shape you can pretty much get it right by tracing the area it sits over on the cap.