Thorssoli's First Order Builds (New Rubber Gaskets on p.9)

Discussion in 'Star Wars Costumes and Props' started by thorssoli, Jul 29, 2015.

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  1. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    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:
    [​IMG]

    The helmet was split up into carve-able pieces that I then cut out on my Carvewright CNC Machine:
    [​IMG]

    After cutting off the waste material and assembling the pieces, it looked like so:
    [​IMG]

    [​IMG]

    Then I soaked it in several coats of primer:
    [​IMG]

    That's when the filler work began on the seams:
    [​IMG]

    [​IMG]

    I also decided to beef up the bottom edge and give it a bit more girth:
    [​IMG]

    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:
    [​IMG]
    Not bad.

    With a little more filling and sanding, I was finally happy with the overall shape:
    [​IMG]

    [​IMG]

    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:
    [​IMG]

    [​IMG]

    Now it's been coated in my standard prototype color awaiting molding:
    [​IMG]

    Since I really needed another project at the same time, I had my modeler make up the snowtrooper parts as well:
    [​IMG]

    Right now they're still too thick to fit over the helmet:
    [​IMG]

    But once they're laid up in thinner material I think they'll be fine:
    [​IMG]

    Those pieces are still in the middle of the prime, sand, prime, sand cycle:
    [​IMG]

    Somewhere along the way I also made a custom base for a display stand:
    [​IMG]

    Stay tuned, more to come.
     
    Last edited: Jul 25, 2018
  2. tk2647

    tk2647 Well-Known Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

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

    Badgersbunk Active Member

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    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.
     
  4. Toddo

    Toddo Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    That flametrooper looks outstanding.
     
  5. mugatu

    mugatu Sr Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Always fascinating.
     
  6. LorduDesign

    LorduDesign Sr Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Really nice job ;)
     
  7. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    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:
    [​IMG]

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

    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:
    [​IMG]

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

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

    pnag Well-Known Member

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    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
     
  9. BobasDent1138

    BobasDent1138 Active Member

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    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
     
  10. guabe

    guabe Well-Known Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Interested on the Snow.
     
  11. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    It'll basically double the price since I'm essentially making two helmets.

    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:
    [​IMG]

    Registration keys added:
    [​IMG]

    Parting wall built:
    [​IMG]

    First half of fiberglass mothermold laid up:
    [​IMG]

    Parting wall removed:
    [​IMG]

    Second half of mothermold laid up:
    [​IMG]

    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...
     
    williamsboy and Toddo like this.
  12. horus

    horus Well-Known Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

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

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Thank you! My builds are nothing if not detailed.

    Yesterday I trimmed the hair off of the edges of the mothermold:
    [​IMG]

    Then I drilled it for bolt holes:
    [​IMG]

    And pried the two halves off:
    [​IMG]

    Then I made a serpentine cut up the back side of the silicone rubber jacket:
    [​IMG]

    And peeled the mold off of the prototype:
    [​IMG]

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

    Then I got excited and rotocast a copy:
    [​IMG]

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

    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:
    [​IMG]

    Here they are mounted to the 3D printed bases and fitted into the protoytpe:
    [​IMG]

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

    While I was waiting for the filler to dry, I sanded the first casting lightly:
    [​IMG]

    Then primed it and sprayed on a couple coats of gloss white:
    [​IMG]

    It came out pretty good for a rattle can paintjob:
    [​IMG]

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

    Looks good to me:
    [​IMG]

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

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

    More to come. Stay tuned.
     
    JPH, williamsboy, dejordzta and 3 others like this.
  14. patrickivan

    patrickivan Active Member

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    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!
     
  15. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Be sure to subscribe. It's only going to get better.
     
  16. Fuzzual

    Fuzzual Sr Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

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

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    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:
    [​IMG]

    I should be pouring the rubber this morning.
     
  18. Steakdaddy93

    Steakdaddy93 New Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    UGGGH! That's looking amazing!
     
  19. alienbuilder

    alienbuilder Well-Known Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    yes! great work!
     
  20. 5xxicemanxx5

    5xxicemanxx5 Well-Known Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Nice work brother impressive
     
  21. stevechewbacca

    stevechewbacca Active Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Very impressive !

    Do you plan to make the TIE pilot too ?
     
  22. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    It crossed my mind. I'll need to get the flametrooper out of my system first though.

    To that end, I boxed up the aerator prototypes for molding:
    [​IMG]

    Then I poured in some rubber:
    [​IMG]

    The mold came out great:
    [​IMG]

    Here's the first casting:
    [​IMG]

    That was basically just to clear the last little bits of the prototype out of the mold. Then I cold cast a pair with aluminum powder and installed them into a helmet:
    [​IMG]

    I'm pretty happy with the end result:
    [​IMG]

    I grabbed an old can of flat black paint and a slightly too large brush and added in the stripes:
    [​IMG]

    I'm calling this one my rough draft:
    [​IMG]

    Next I'll be painting one up with proper automotive paints and clearcoat for that First Order shine.

    I'll also be installing a bit of tinted acrylic into the eye slit and adding some breathable mesh to the mouth hole.

    Stay tuned...
     
    dejordzta and Toddo like this.
  23. Toddo

    Toddo Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    I can't wait to get my hands on a finished one.
     
  24. ABE

    ABE Well-Known Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    amazing work
     
  25. stevechewbacca

    stevechewbacca Active Member

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    Re: TFA Flametrooper (and Snowtrooper) Helmet Build

    Ok thanks :D
     
  26. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    Out of the workshop for a couple of days, so it's time to focus on the digital side:
    [​IMG]

    I've also changed the thread title from "TFA Flametrooper (and Snowtrooper) Helmet Build to "Thorssoli's Episode VII Builds."

    It's about to become a better description of what's coming...
     
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  27. virateck

    virateck Active Member

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    Re: Thorssoli's Episode VII Builds

    You have to do new pilotes !!!! :lol:love
     
  28. msleeper

    msleeper Sr Member

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    Re: Thorssoli's Episode VII Builds

    Phasma? Well now I'm interested.
     
  29. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    I have to? Okay. I guess I have to. Are there any images of the back side of the helmet yet?

    Good to know. Any chance you'd be interested in contributing any digital sculpting skills to the effort?
     
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  30. TheSteveRosario

    TheSteveRosario New Member

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    Re: Thorssoli's Episode VII Builds

    Awesome work! I hope you don't mind I thought I'd try on the Flametrooper helmet haha
    Flametrooper Steve 3 (EXP).jpg
     
  31. msleeper

    msleeper Sr Member

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    Re: Thorssoli's Episode VII Builds

    Definitely! I was eyeing making her rifle anyway.
     
  32. stevechewbacca

    stevechewbacca Active Member

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    Re: Thorssoli's Episode VII Builds

    Not yet. May be with the action figure release.
    I guess it's basicaly a flametrooper with storm visor and a moving visor on the top.
     
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  33. Bogleo

    Bogleo Well-Known Member

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    Re: Thorssoli's Episode VII Builds

    I can also help, if you want.
     
  34. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    Looks good. Let me know if you'd like to get one for yourself. I've got a run going in the classifieds.

    I should be starting on the pilot in the coming week. Looks like there's really nothing to see on the back of the helmet.

    Sounds good. Shoot me a PM when you get a chance.

    UPDATE:

    The Phasma helmet parts are all cut out:
    [​IMG]

    Of course, laid out like that, they don't really look like much. Here's the bottom half assembled:
    [​IMG]

    Here I am filing out some of the thickness on the inside to make it so my head will fit inside (the material is 3/4" thick in places):
    [​IMG]

    Here it is in between a couple of clone trooper helmets for reference. The one on the left is a clonesix helmet and the one on the right is the same size as the MR EpIII helmets:
    [​IMG]

    The Phasma helmet is pretty much the same size as my eFx stormtrooper helmets. I'll dig one of those out and get a side-by-side pic soon.

    In the meantime, here's a pic of me wearing the prototype:
    [​IMG]

    [​IMG]

    And finally, here's the prototype in primer:
    [​IMG]

    Little dog approves:
    [​IMG]
     
  35. Ponte

    Ponte Active Member

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    Re: Thorssoli's Episode VII Builds

    Looks awesome so far! Can't wait to see the castings.
     
  36. pnag

    pnag Well-Known Member

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    Re: Thorssoli's Episode VII Builds

    Looks really good! And you can do the, in something that will buff like chrome? Hmm.... Interesting! :D
     
  37. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    Here's a couple of helmets I chromed a while back:
    [​IMG]

    I've gotten better at it since then.
     
  38. pnag

    pnag Well-Known Member

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    Re: Thorssoli's Episode VII Builds

    Wow! So it would look pretty * fantastic!
     
  39. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    I hope so. For right now I'm doing a lot of smoothing on the prototype. This morning it looked like so:
    [​IMG]

    Then I added some filler:
    [​IMG]

    And did some sanding:
    [​IMG]

    And a bit more filling and sanding:
    [​IMG]

    Then I sprayed on a coat of primer to see how it was going:
    [​IMG]

    It looks even better with the grill insert in place:
    [​IMG]

    Right now it looks about like so:
    [​IMG]

    The teardrop details and grill aren't fixed in place yet. I'll be doing that after I'm done with all of the really rough filling and sanding is done.

    Here's another shot in profile:
    [​IMG]

    Finally, here it is next to my Master Replicas stormtrooper bucket for scale:
    [​IMG]

    More progress tomorrow. Stay tuned...
     
    dejordzta, Cameron and stevechewbacca like this.
  40. DlarianFerrel

    DlarianFerrel Active Member

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    Re: Thorssoli's Episode VII Builds

    Any idea how much Phasma will be? I figure more than the others since it is chromed.
     
  41. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    I'll send you a PM. In the meantime, you should check out this thread: LINK.
     
  42. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    Progress continues:
    [​IMG]

    Here's how it looks right about now:
    [​IMG]

    Smoothing will continue tomorrow. My next batch of silicone will arrive tomorrow as well.

    Stay tuned...
     
    Epona_Rhi likes this.
  43. Epona_Rhi

    Epona_Rhi Well-Known Member

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    Re: Thorssoli's Episode VII Builds

    I am always jealous when I see your work... and your workshop :D Good job with those helmets!
     
  44. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    Thanks a bunch. They're coming right along.

    The other day I decided I didn't like the placement of the groove along the bottom edge of the helmet, so I filled it in:
    [​IMG]

    Then I scribed a line along the bottom that matched the offset for the groove around the frown and carved it out with a triangle file. It looks much better now:
    [​IMG]

    One of the guys that helps me out in the shop from time to time is almost as tall as Phasma is supposed to be, so I had him try on the helmet:
    [​IMG]
    He's a little scrawny, but the proportions still look pretty good.

    Sitting on the floor in front of him, you can just start to see the bottom of his chin under the helmet:
    [​IMG]

    So after a bit more sanding and smoothing, I sprayed on a nice, glossy coat of paint:
    [​IMG]

    Before anyone gets excited and thinks the color is some sort of statement about the fact that it's a woman's helmet, please understand that my prototypes are almost always painted pink:
    [​IMG]

    So here's where it sits right now:
    [​IMG]

    Today I'll be filling in a few tiny imperfections that were revealed by the gloss coat and then it'll get a bit more smoothing and polishing before I spray on yet another coat of glossy, lightish-red paint and hopefully I'll start the molding over the weekend.

    Stay tuned...
     
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  45. pnag

    pnag Well-Known Member

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    Re: Thorssoli's Episode VII Builds

    That looks awesome! Giddy with excitement for that :)
     
  46. GUARD1AN

    GUARD1AN Member

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    Re: Thorssoli's Episode VII Builds

    This thread is so full of win !!! BTW I googled that carvewright eyyeeeeeeee starting at $2,100, but * can it do some cool things, how did you break the 3D design up into all the different sections ??

    -Mike
     
  47. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    There's an "STL Importer" add-on to the software that allows you to import 3D files and slice them up into pieces that the 3-axis CNC machine is able to carve. This is basically how I made the large parts for my MkIII Ironman suit:

    [​IMG]
    You can read about it here: http://www.therpf.com/showthread.php?t=170665

    The rest of the Phasma suit should be easy by comparison.

    Of course, the first prop project I used that machine for was my Halo M6G Magnum Pistol:
    [​IMG]

    That one seemed like a really big deal at the time. How time has passed...
     
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  48. Psicorp7

    Psicorp7 Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    I always know you're getting close to done when you break out the "Light Red"! :lol

    Great Work!
     
  49. Sluis Van Shipyards

    Sluis Van Shipyards Master Member

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    Re: Thorssoli's Episode VII Builds

    I have to say that's a pretty darn cool way to use a cnc wood router! I didn't even know you could break the file down and have it cut it out like that.
     
  50. thorssoli

    thorssoli Sr Member RPF PREMIUM MEMBER

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    Re: Thorssoli's Episode VII Builds

    Funny thing, I ran out of light red yesterday and had the helmet ready for a gloss coat. So now I present to you LIME GREEN PHASMA:
    [​IMG]

    [​IMG]

    I really thought I'd nailed it, but it looks like I need a bit more filler work before I can call this thing ready to mold. Soon...

    In the meantime, I started tweaking one of my reject flametroopers to make the beginning of the snowtrooper helmet:
    [​IMG]

    So that's starting off great.

    Stay tuned...

     
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