Vader ROTJ Helmet build from a warped casting (pic heavy)

[lethyry]

the bottom of the dome skirt isnt super bevelled, its more the sides along the face that are really bevelled in, may be from sanding or from the changes made from the ANH to ESB buts its quite noticable.

 

[Too Much Garlic]

A picture of the ESB stunt helmet for reference.

 

[Imperial Weapon]

A picture of the ESB stunt helmet for reference.

View attachment 1560668

cheers its just a real shame that I sanded that away because I thought the EFX dome had a had a rather 'tapered' (I think thats the word) in wards look to it on the right side heres a comparison between EFX and Warren

 

[Imperial Weapon]

Bin back at it again I taped the outside of the helmet and put in some fibreglass filler theres more to come yet as far as strengthening and resurfacing goes but I just wanted to at least get it back in all one piece for now.

 

[Imperial Weapon]

I'm back I decided to smash away the filler after someone I know tripped over it... anyways I replaced that with aluminium tape which was applied fairly thick on the helmet so I could bend it (mostly) to the shape I wanted and fibreglassed the inside of it, irlt was so hot today that I wasted two damn mixtures!!! so I had to do it in smaller amounts.

 

[lethyry]

those helmets specifically are a pain to work with IMO I had one previously and I decided to part with the dome and just do a prop accurate ANH faceplate instead, i wasn’t a fan of the fibreglass work as well mine was severely damaged when I took apart the faceplate and dome. Props to you for sticking with it.

 

[Imperial Weapon]

those helmets specifically are a pain to work with IMO I had one previously and I decided to part with the dome and just do a prop accurate ANH faceplate instead, i wasn’t a fan of the fibreglass work as well mine was severely damaged when I took apart the faceplate and dome. Props to you for sticking with it.

Cheers man I mean I do have a long nasty air pocket on the dome on the right side but I'll just dig it up and fill it with the glass filler also when you say yours was severly damaged when you took apart the dome your talking about the same helmet I bought right? because if you are you can't avoid that no matter how skilled you may be and yeah that silicone is a pain in the bum to get rid of.

 

[lethyry]

Cheers man I mean I do have a long nasty air pocket on the dome on the right side but I'll just dig it up and fill it with the glass filler also when you say yours was severly damaged when you took apart the dome your talking about the same helmet I bought right? because if you are you can't avoid that no matter how skilled you may be and yeah that silicone is a pain in the bum to get rid of.

Yep I got the same helmet you have now. I got it for a decent price since it had a crack in the neck (which got even worse during shipping though lol) but the main faceplate and dome were stuck together and I was prying them apart but the top of the faceplate was so thin I just said screw it and broke the top off the faceplate, I’ve replaced it similar to you with no ring. Yep the silicone was a joke to get rid of. Especially with the lenses.

 

[Imperial Weapon]

Yep I got the same helmet you have now. I got it for a decent price since it had a crack in the neck (which got even worse during shipping though lol) but the main faceplate and dome were stuck together and I was prying them apart but the top of the faceplate was so thin I just said screw it and broke the top off the faceplate, I’ve replaced it similar to you with no ring. Yep the silicone was a joke to get rid of. Especially with the lenses.

I found that a basic kitchen knife believe it or not is the best way to seperate the dome and the face do you have a thread on your build?

 

[lethyry]

I found that a basic kitchen knife believe it or not is the best way to seperate the dome and the face do you have a thread on your build?

No i don’t have a thread for it it’s something I mess with in between commissions when I have the odd bit of time . I never really bother with doing threads for my builds given most of the stuff I do is for other people, lol,

 

[Imperial Weapon]

No i don’t have a thread for it it’s something I mess with in between commissions when I have the odd bit of time . I never really bother with doing threads for my builds given most of the stuff I do is for other people, lol,

Oh well thats fair enough anyways I enjoyed viewing the idealised ESB thread.

 

[Imperial Weapon]

so bad news upon snading I found out that one side is warped, damn looks like I'll be duin more fibreglassing when I get some more, now I' not sure if the dome suffers too much swell I compared it to my new image dome and its near enough the same size but when I try to approximate the positioning it seems slighlty oversize thoughts?

 

[lethyry]

You will have a hard time with trying to see how the dome fits with the faceplate without the ring mount being done on the faceplate and having the dome actually sit on it. using your hand to try and line them up wouldnt work. from what i can see the dome looks good.

 

[Imperial Weapon]

You will have a hard time with trying to see how the dome fits with the faceplate without the ring mount being done on the faceplate and having the dome actually sit on it. using your hand to try and line them up wouldnt work. from what i can see the dome looks good.

comming from a guy who has or had MW helmets that comment is one big relief.

 

[lethyry]

coming from a guy who has or had MW helmets that comment is one big relief.

yep from the picture you posted the dome looks to be fine how it is,obviously i'd not do too much to the dome until you get the ring mount for the face sorted out and see how the dome sits on it. i usually do it that way myself is finish the bodywork/priming faceplate and then the dome. if you do find once you get the dome sitting on the faceplate, its a bit wide or flared. you can always heat form the dome slightly and readjust the shape.

 

[Imperial Weapon]

yep from the picture you posted the dome looks to be fine how it is,obviously i'd not do too much to the dome until you get the ring mount for the face sorted out and see how the dome sits on it. i usually do it that way myself is finish the bodywork/priming faceplate and then the dome. if you do find once you get the dome sitting on the faceplate, its a bit wide or flared. you can always heat form the dome slightly and readjust the shape.

not neccessarily I did fibreglass the intirior of the dome.

 

[lethyry]

Yea I guess you’re right depending on how thick you went on the fibreglass. I usually do the heat forming before I add the glass but I have gotten away with doing it after.

 

[Imperial Weapon]

Yea I guess you’re right depending on how thick you went on the fibreglass. I usually do the heat forming before I add the glass but I have gotten away with doing it after.

Well I did with the slit cutting the more I look at this helmet the more I notice the EFX PCRs flaws such as the nose indentions beimg too wide etc etc.

 

[lethyry]

Well I did with the slit cutting the more I look at this helmet the more I notice the EFX PCRs flaws such as the nose indentions beimg too wide etc etc.

ah well then if you did the slit cutting the dome should be fine then, the difference making that specific dome more esb/rotj shape was slight, so it should be fine now, yea the PCR is quite different with the nose/nose slots being the biggest flaw in my opinion.

 

[Imperial Weapon]

Wow can't believe its been 2 yrs my goodness!! anyhow decided to pick this thing back up and fix the back of the head with some dremmeling and bending and then I'm gonna reglass those parts, I taped the corner into shape I will lay more material over that part when its done.