WIP: "Darth Ugly" ANH Helmet Build

[clonecollector]

This will document my buildup of the "Darth Ugly" ANH helmet. I couldn't find one here already so I decided to make one.

Here is the helmet out of the box and placed on a mannequin. I'll be using various ideas I've seen employed on different forums to assemble this helmet and make it wearable.

This will be a trooping helmet so I have to build it so that I can take it on and off easily and have a good amount of airflow. I'm not going to install fans initially but plan to do that in the future.

The photos aren't great as I only had my phone camera.

 

[clonecollector]

The first thing I needed to do was figure out how to mount the dome securely so that I can slip the helmet on and off. I decided to bolt it on. I made two marks where I wanted to slip bolts through.

 

[clonecollector]

Now I mark out where to CA glue bolts onto the dome. To do that I fit the mask and dome back together until I had the dome placed where I thought it looked good. Then I turned the helmet upside down and marked the holes with a Sharpie.

The bolts will be reinforced with JB Weld.

 

[clonecollector]

Here we are with bolts CA glued in to determine the correct position. I had to widen the forward hole in the mask mounting ring to get the bolt to slide in easily. Not a pig problem though.

 

[clonecollector]

Now I used JB Quick with wide washers to secure the bolts into the dome. I will eventually go back to cut the excess from bolts with my dremel after I mark them.

 

[clonecollector]

This shows how the dome and mask align inside and bolted together. It feels nice and secure.

 

[clonecollector]

This is where I'm at right now. The dome and mask are attached securely.

My next step is to fasten a hardhat liner inside the mask. Hopefully I can work on that tonight!

 

[CSMacLaren]

Oh WOW! That first shot just about took my breath away. I'm glad Ugly still looks good despite the cameraphone photography. I love how its neck wraps itself around the neck of your mannequin - or is that you in there?!

In theory, if you don't foam up the entire interior but use blocks, the space that's not taken up by foam will also facilitate airflow.

What make is your leather suit? If your suit allows it, I suggest trying to deepen your chest.

May I use that picture of the dome mounting system?

Going to watch this thread! :thumbsup

 

[clonecollector]

Hey Mac!

Feel free to use whatever you can take.

Right now I have the helmet on a mannequin. Its a very thin Perry Ellis mannequin... not in the most masculin of poses either. lol!... but I got it for free so I can't complain. I used it to work on my old ESB Fett and it helped alot.

I'm a "stocky" guy personally so I think I'll be able to fill out the armor and suit.

The suit itself is a three piece leather suit from Custom Props.

Thanks for the encouragement!

Oh WOW! That first shot just about took my breath away. I'm glad Ugly still looks good despite the cameraphone photography. I love how its neck wraps itself around the neck of your mannequin - or is that you in there?!

In theory, if you don't foam up the entire interior but use blocks, the space that's not taken up by foam will also facilitate airflow.

What make is your leather suit? If your suit allows it, I suggest trying to deepen your chest.

May I use that picture of the dome mounting system?

Going to watch this thread! :thumbsup

 

[clonecollector]

OK. I had about an hour to work on this today so I decided to mount the hardhat liner. I eyeballed where the pilot holes for screws would go. I also taped in the liner to get a sense of how high it would sit.

While drilling the pilot holes I cracked some of the black top coat of the fiberglass. I used JB Kwik to refill the area. Its reallu stron again now. All I have to do is add some spot filler to smooth it out and use wide washers on both sides for support.

 

[clonecollector]

Here we are with the hardhat liner installed. It floats in there but I don't think I need another set of screws. The ability to tilt inside seemed to let me take it on and off easier. Once I have the chest armor I can guage if I need to revisit this mounting system for fine tuning.

 

[clonecollector]

Here are a couple of pictures with the hemet on me. I've worn Boba Fett and Clonetrooper helmets and this one seems to have ALOT of room inside compared to those!

Without armor I'm reminded of Dark Helmet from Spaceballs!

 

[bookface]

Looking good so far, like it!

 

[clonecollector]

Looking good so far, like it!

Thanks!

 

[CSMacLaren]

Well done, Bookface! I hadn't seen a side shot of the mask (or, at least, remember that I had). These shots had me going there - I thought I was looking at a 20th Century for comparative purposes. Then I thought, wait, there's more shots of this thing... what the heck is a 20thCent doing on this thread? Kudos! :thumbsup

 

[CSMacLaren]

Cloney,

Just curious, why are you making the helmet permanently attached to the mask? Most just use velcro on the mask's forehead. Or is the head opening large enough for you to not want to bother with this being a 2-piece configuration?

 

[clonecollector]

Cloney,

Just curious, why are you making the helmet permanently attached to the mask? Most just use velcro on the mask's forehead. Or is the head opening large enough for you to not want to bother with this being a 2-piece configuration?

I've seen the trooping helmet that Darth Stone makes. His are bolted on like that and use a hardhat liner as well.

After doing these modifications myself now I see the logic in how his system works.

If the dome is bolted on it won't shift and I'll always have a specific look to the helmet. If i ever need to reposition the dome its only a matter of loosening two nuts.

I'm lucky too that my head fits easily in and out of the helmet. I also wanted to be able to put the helmet on myself.

 

[clonecollector]

Here is where I'm at now. Washers have been glued on to the outside and inside of the mask for support. I used JB KWIK for added strength. Afterwards I smoothed everything out with a bit of Bondo spot putty.

 

[clonecollector]

Here are some quick shots of the interior with washers glued in as well. This way they won't slide around or fall out during the mounting of the hardhat liner or dome.

 

[CSMacLaren]

Fascinating. How do you calibrate your head height with how far up the hardhat liner has to be positioned within the Ugly mask?