Before things get too confusing regarding the "TM" ESB Vader helmet, I'd like to clarify/add/correct/comment on a few things which I think are of importance. Just for clarification, TM are my initials, I am known as vadermania on the forums, and I work as a VFX Supervisor in the movie business in Germany.
According to the previous owner and based on my personal research, the so-called "TM ESB Vader helmet" has been made for the production of ESB by the very same person who produced the majority of fibreglass helmets for the movie. It was made to be used as a lighting reference on set, before the actors were called in. If it has ever been used as such is not proven yet. For now, I am not able to present waterproof documents regarding it's authenticity, but this might change in the near future.
Partly correct. I never touched the dome (it still has it's original paint on it), only the faceplate after it has been separated from the dome.
There were two layers of paint (gunmetal and black) on it, a heavy layer of light grey primer, plus some reddish bondo - all this has been removed by me using acetone. The first part I stripped (as a test actually) was the area around the tabs. I could see no traces of sanding in that area, which encouraged me to continue with the stripping.
Pictures of the faceplate in this state are already floating around on this forum - some photoshopped, some not. Let's have a look at the photo below - the one entitled "stripped down TM casting all surfaces sanded down". This image shows the ORIGINAL TM faceplate after the paint, primer and reddish bondo has been removed by me via acetone. This image is NOT photoshopped. Perhaps it is a bit out of focus in the area in question. What you can see here is that the faceplate has been sanded in some areas, but not completely. For example, the areas that have been sanded most extensively are Vaders right side cheek above the upper tusk tube, the area right from Vaders right tear duct and Vaders left eyebrow. I addition to that, the complete forehead above the eyebrows has been sanded lightly.
To be honest, when I examined the faceplate after the paint had been fully removed, I was slightly disappointed, because I thought there was a lot of detail missing. But I also noticed that there was other material slopped onto the surface of the faceplate which could not be removed via acetone. It was some sort of black resin or resin bondo. You can spot it very clearly in the image below, sticking on Vaders right eyebrow.
Not correct. JRX/Jesper worked on the ORIGINAL faceplate. After I have sent the original faceplate to Jesper (with the intention only to restore the broken tusks), he found out, after further examination, that the black resin (which in fact was applied very sloppily on the faceplate) could carefully be scratched away with a fingernail or a toothpick. The black resin was found on many areas of the faceplate, most notably on the eyebrows and in the eyebrow sockets, the nosebridge, the mouth area, Vaders right cheek and the area around the left tearduct. It took Jesper literally ages to remove this material, revealing the detail underneath.
Of course there were areas which had imperfections such as air bubbles and tiny holes - those were filled in by Jesper.
The ORIGINAL, restored faceplate was molded by Joerg. At that time, the faceplate had two details incoroprated to identify recasts. One was a little sculpted "TM ESB" logo. When the faceplate was molded for the second time, these details were removed prior to molding.
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