I started modifying mine today. My goal is to make a passable ANH-style helmet for basic 501st approval for my girlfriend.
- Took everything out of the helmet, including the tabs that connect the pieces together. The helmet is MUCH lighter as a result. Currently have the helmet held together with masking tape.
- Ripped out the false rubber material from the neck opening. The interior of the helmet will need some cleaning up before I can fit the accurate rubber S-trim.
- Applied Bondo to the recessed tube stripes, the recessed vent lines on the tears and traps, the ear caps, the battery cover, and the speaker holes.
I'm planning to carve out the 4 ear bumps with my Dremel. Everything will be sanded smooth and a couple coats of gloss white spray paint will be applied to the whole helmet after masking off the vocoder and mic tips.
Once the spray paint is cured, I'll be painting on the tears, traps, tube stripes, and frown with the correct paint colors.
I'll come back with pictures once I finish up the whole thing.