Royal Guard Helmet project

[darkjawas]

last year or so while looking for a RG helmet to start a shadow guard from the forced unleased game started looking for a helmet
what i found was a Don post helmet for a good price (on ebay)
what i got not only a don post helmet that was cracked but a urethene mold
as well contacted seller and it was part of the listing

i repaired the helmet and went along with making a shadow rg
last month the helmet got dropped on the ground when a few kids where drooling over it at this point it be a while to repair

so i pulled out the mold from storage and started playing around with little girl watching me (she loves watching props being built)
instead of just casting a helmet and painting it ive decided to remake a helmet
that will be little larger then the standard DP
PLUS I DONT WANT TO JUST RECAST AND GO ON

so i smooth on casted a helmet from the mold and took the dremell to it
so far ive cut the casted helmet into 3 and a half parts and will be expanding it 1/4 in maybe a little larger than 1/4 if need
this weekend ill be gluing the shims/supports for the parts to be reassembled with gaps for expanded helmet

not sure if want to use air dry clay,bondo, fiberglass resin jelly (fiberglass bondo), paper mache
i plan on making a silicone mold once the expanded helmet id finished and smooth for mold process so if i break a helmet i can make a new one
(with 2 kids helmet and prop breaking happends sometimes :lol)

pics here
usefull input is welcome for ideas to cont progress

 

[darkjawas]

started gluing in shims/connectors using what i have laying around
in this case shims are sintra with Jb weld glue w/ hot glue to hold in place along with clamps (note to self need more clamps)

 

[darkjawas]

brushed this prodject off the backburner
since a few of us are making RG costumes

 

[maverick1255]

Looking good. Keep posting updates.

 

[darkjawas]

finally finished not sure if have the correct red color thou
debating on making a mold of this ????

 

[Sourdoh]

I have seen the original Helmets. I knew a member of the crew that made them for Star Wars (Ep IV) back in the day. I saw the one he had.

Of course, it is almost impossible to tell true color from a photo on the internet, but the photo here looks a little to the pink side. The originals were true red.

 

[darkjawas]

going thru the home depot paint store later in the week to get several
cans of red to repaint.
in the next month will start the mold to cast these