Thorssoli's First Order Builds - Captain Phasma FINISHED on Page 21!

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thorssoli

Sr Member
RPF PREMIUM MEMBER
When I got back from Celebration Anaheim, I got a wild hair and decided I'd really like to make one of the helmets from the upcoming Star Wars. I got a hold of a friend who does a lot of 3D modelling for me and sent him all of the reference images of the flametrooper I could find. Here's what he sent back:
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The helmet was split up into carve-able pieces that I then cut out on my Carvewright CNC Machine:
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After cutting off the waste material and assembling the pieces, it looked like so:
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Then I soaked it in several coats of primer:
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That's when the filler work began on the seams:
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I also decided to beef up the bottom edge and give it a bit more girth:
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Somewhere in the middle of that whole rush, a friend stopped by with one of the Anvos helmets and I got to compare it for size:
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Not bad.

With a little more filling and sanding, I was finally happy with the overall shape:
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After that, it was just a matter of fine sanding and primer and more sanding and more primer and so on until it looked like so:
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Now it's been coated in my standard prototype color awaiting molding:
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Since I really needed another project at the same time, I had my modeler make up the snowtrooper parts as well:
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Right now they're still too thick to fit over the helmet:
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But once they're laid up in thinner material I think they'll be fine:
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Those pieces are still in the middle of the prime, sand, prime, sand cycle:
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Somewhere along the way I also made a custom base for a display stand:
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Stay tuned, more to come.
 
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tk2647

Well-Known Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

wow...great work....thanks for sharing your progress !
 

Badgersbunk

Active Member
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

The first image of it being worn in mdf reminds me of Lego. it's looking good, even in pink.
 

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thorssoli

Sr Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

Thank you all for the positive feedback. Apologies for the lack of updates. I had a commission project that took over the whole workshop for the past few weeks and haven't really had time for hobby projects.

That said, today I finally got around to starting the mold. I began by adding a cardboard standoff to the bottom of the helmet:


Then I mixed up a thick batch of silicone and filled in all of the undercuts:


Once that had started to set up, the whole thing was flipped over and mounted to a piece of cardboard with a drip lip built up around the helmet. Then I poured on a print coat to pick up all of the surface details:


In other news, I've done the tiniest bit of smoothing to the snowtrooper dome:


I should have the mold done in the next couple of days. Stay tuned...
 

pnag

Well-Known Member
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

Looks great! Will the snowtrooper dome add much to the overall cost? I'm down for the helmet, but would probably like to get the dome too, budget permitting :D
 

BobasDent1138

Active Member
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

Oh man these are looking sweet! Any price range for the flametrooper yet?

Sent from my SAMSUNG-SM-N910A using Tapatalk
 

guabe

Well-Known Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

Interested on the Snow.
 

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thorssoli

Sr Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

Looks great! Will the snowtrooper dome add much to the overall cost? I'm down for the helmet, but would probably like to get the dome too, budget permitting :D
It'll basically double the price since I'm essentially making two helmets.

Oh man these are looking sweet! Any price range for the flametrooper yet?
PM sent. Also, I've got a thread going in the Junkyard: http://www.therpf.com/showthread.php?t=241417

UPDATE: the main body of the helmet has been molded. Here's some progress photos:

Thickening the rubber:


Registration keys added:


Parting wall built:


First half of fiberglass mothermold laid up:


Parting wall removed:


Second half of mothermold laid up:


So I should be able to pull the prototype and rotocast a couple of copies of the helmet today. I'm still not happy with the shape of the aerators, so it'll be a minute before I'm ready to mold those.

More to come, stay tuned...
 

horus

Well-Known Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

Great Work , I love the detail of the build thanks.
 

thorssoli

Sr Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

Great Work , I love the detail of the build thanks.
Thank you! My builds are nothing if not detailed.

Yesterday I trimmed the hair off of the edges of the mothermold:


Then I drilled it for bolt holes:


And pried the two halves off:


Then I made a serpentine cut up the back side of the silicone rubber jacket:


And peeled the mold off of the prototype:


Once that was done, I cleaned up the mothermold a bit and put the whole thing back together:


Then I got excited and rotocast a copy:


The mold was almost flawless except for these tiny little bumps under the eye slit:


Fortunately, it takes about fifteen seconds with some 220-grit sandpaper to make them go away.

In other news, I decided I didn't like the 3D printed aerators that I'd made, so I took a scrap of acrylic rod to the lathe and made the beginnings of the aerators:


Here they are mounted to the 3D printed bases and fitted into the protoytpe:


Then I added the last little detail to them before smearing on some filler putty to fill in the seam areas:


While I was waiting for the filler to dry, I sanded the first casting lightly:


Then primed it and sprayed on a couple coats of gloss white:


It came out pretty good for a rattle can paintjob:


Once it was dry enough to handle, I had the Lady Shawnon try it on:


Looks good to me:


But since I made a mold, I feel compelled to make more than one of them:


It's possible I have a bit of a problem...

More to come. Stay tuned.
 

patrickivan

Well-Known Member
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

This may be my first post, though a long time therpf lurker.

This build, step by step, was a pleasure to watch. Just: wow!
 

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Fuzzual

Sr Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

and i purchase one of these beauties where? . . .
 

thorssoli

Sr Member
RPF PREMIUM MEMBER
Re: TFA Flametrooper (and Snowtrooper) Helmet Build

and i purchase one of these beauties where? . . .
PM Sent.

I didn't manage to get the aerators molded yesterday. I wanted to make sure that the paint would have plenty of time to dry:


I should be pouring the rubber this morning.
 

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