Top Gun: Maverick and Dead Goose.

Hasenbrau

New Member
Hello all and a belated Happy Halloween!

I just wanted to share my Halloween costume(s) and build this year. Maverick and Dead Goose! This setup was a blast to wear and actually won my buddy and I first place at our company Halloween party with a bit of nostalgia and morbid humor.
Party_PictureBooth_01_o.jpg

Party_PictureBooth_02_o.jpg


While not nearly as ambitious as last years costume: http://www.therpf.com/f24/warhammer-40k-space-marine-full-scale-new-wip-breakdown-163509/ I still found this 2 man costume setup a bit challenging in it's own right, mostly in trying to track down the right kind of gear without having to take out a second mortgage. Fortunately I had a family friend and retired USAF pilot, who was able to help me identify all the gear used in the movie so I knew what I was looking for going into this.

I had a good time going into bargain hunting mode, as well as recreating the flight helmets from the movie. Some stuff's not 100% accurate, but often that meant the difference between 50 bucks and 500. Still, this stuff will run you more than some foam and spray paint. ;)

Here's WIP photos and breakdown. Thanks for looking:

Maverick Helmet from old Gentex shell HGU-33:
MaverickHelmet_Completed_o.jpg


WIP:
I got this helmet in pretty good shape but still obviously past it's usable service date. The two MBU masks were hard to come by and acquired separate from the the helmets. One is actually missing a number of internal components as well as a comm cable.
Maverick_helmetStartAndMasks_o.jpg


Stripping it down. The edgeroll foam on these old flight helmets are generally gone if the things are dated a decade or more. The leather was also torn and cracked:
MaverickHelmet_WIP_01_o.jpg

MaverickHelmet_WIP_02_o.jpg


I skipped a few wip images here, but similar to the Goose helmet: Old reflective tape was removed. Clear coat and paint was stripped, un-needed holes were filled. Then helmet was primered, painted in a dark blue metalic (like the film) and clear coated.
MaverickHelmet_WIP_03_o.jpg


The protective foam and leather covering inside this helmet wasn't too bad off. I cleaned it up and restained a few spots and saved it for reuse:
MaverickHelmet_WIP_04_o.jpg


Using the old edgeroll leather as a guide, I cut new leather pieces and stitched them to the helmet:
MaverickHelmet_WIP_05_o.jpg

Replacement open-cell edgeroll foam from a proper flighthelmet supplier is 60+ bucks and takes weeks to get. Seeing as how I had only a few days to put together these helmets, I used pool noodles (it's the same stuff for about a buck).
MaverickHelmet_WIP_06_o.jpg

Glued in place:
MaverickHelmet_WIP_07.jpg

Next came the taping. I decided I was going to use reflective tape as would have been used on a real Naval aviator helmet of the era. Obviously the movie props used no reflective tape to avoid unwanted reflection on film. This took some measuring and my eyeballs:
MaverickHelmet_WIP_08_o.jpg

MaverickHelmet_WIP_09_o.jpg

MaverickHelmet_WIP_10_o.jpg

I did both visors at the same time (Note the Goose visor is not the correct type, but close enough. I had also originally intended to smash it up)
MaverickHelmet_WIP_11_o.jpg

Lots of little sticky triangles
MaverickHelmet_WIP_12_o.jpg

Once the new edgeroll was cut to size and glued in I was able to wrap the leather and glue the inside edge.
MaverickHelmet_WIP_13_o.jpg

MaverickHelmet_WIP_14_o.jpg

Putting the salvaged headliner back in. Also, for the Maverick helmet, I rewired the headphones.
MaverickHelmet_WIP_15_o.jpg

Mostly assembled:
MaverickHelmet_WIP_16_o.jpg


Next post: Main helmet detailing.
 
Continuing WIP picks of Maverick and Goose Helmets:

I've got a good friend who has a vinyl decal printer, so for things like the eagles and the text on the helmets, I did up some patterns on the computer and had him print them out for me. Since I was using reflective tape, these mostly just served as a guideline to trace over, but boy were they helpful.
MaverickHelmet_WIP_17_o.jpg

Here the beak is reflective tape, the rest of the white portion of the eagle is vinyl and later removed. The reason the back doesn't fit correctly is because I didn't "measure twice." But this was corrected with the reflective tape.
MaverickHelmet_WIP_18_o.jpg

MaverickHelmet_WIP_19_o.jpg

MaverickHelmet_WIP_20_o.jpg

MaverickHelmet_WIP_21_o.jpg

Blurry but shows how the helmet sits on the head
MaverickHelmet_WIP_22_o.jpg


Next up is the Goose Helmet.
 
Here's the WIP pics for the Goose Helmet. This helmet wasn't quite in as good a starting shape as the Maverick helmet, but what can you expect for 40 years old. Here's what it started out as:
GooseHelmet_Start_01_o.jpg

GooseHelmet_Start_02_o.jpg

GooseHelmet_Start_04_o.jpg

Again, rotten foam.
GooseHelmet_Start_05_o.jpg

Once the leather edgeroll and interior foam was removed, I went to work with the razor blade removing old, brittle reflective tape.
GooseHelmet_WIP_02_o.jpg

GooseHelmet_WIP_01_o.jpg

GooseHelmet_WIP_03_o.jpg

Then some holes were filled.
GooseHelmet_WIP_04_o.jpg

Primered and painted.
GooseHelmet_WIP_05_o.jpg

GooseHelmet_WIP_06_o.jpg

GooseHelmet_WIP_07_o.jpg

GooseHelmet_WIP_10_o.jpg

As mentioned with the Maverick helmet images, I taped the Goose visor at the same time. For the Eagle on the Goose helmet, my buddy didn't have any blue vinyl, so we used black car wrap (which he did have). This stuff is great as it's a bit stretchy and air bubbles just push out so easier to use than the vinyl.
GooseHelmet_WIP_12_o.jpg

Again, the white parts of the eagles don't meet. This was how far I took the helmet for the party as I ran out of time. Eventually I intend to finish the reflective tape at which point you'll no longer see any of the black. Also, note the preexisting damage on the back of the visor cover. I figured this was suitable for "dead goose." I have actually purchased a brand new HGU-33 visor cover that I intend on taping up for an undamaged version as well.
GooseHelmet_WIP_13_o.jpg

GooseHelmet_WIP_14_o.jpg
 
"You see, I've got another problem! I need to send someone to Miramar....I I still can't believe it. I've gotta give you your dreamshot...you two CHARACTERS are going to topgun!"

Love it. Nicely done.

And you outbid me for the whale helmet....sigh
 
I mentioned not too long ago that my best friend and I need to do this for a costume party at some point. Her wedding was a little over a week ago. During my speech I mentioned she is the Goose to my Maverick.

Love this. Great job!
 
Awesome job! Well deserved company costume contest win.
The details are amazing.

My eldest son and I did a quick down and dirty Mav and Goose for my daughters Halloween dance. I can attest to the potential budget blowout with this particular costumes. No where near your invested time and $$$ but we had fun repping the iconic movie :)
tyreguny.jpg
 
Thanks for the compliments guys.

tictoc: If it makes you feel any better, that Whale helmet was a lot rougher than the auction let on. Were you going to make something out of it?

2007brandony: Great costumes yourself. Did you do the tapping work on your helmets or were you able to pick those up somewhere?
 
I was just trying to be funny.

I was going to do the same thing with the helmet. I have no problem that you won the auction, I just thought it was funny seeing it here. Actually it was really cool to see you turn it into Goose. I love threads with works in progress...for several posts I just lived vicariously through you! :thumbsup
 
Here's the WIP pics for the Goose Helmet. This helmet wasn't quite in as good a starting shape as the Maverick helmet, but what can you expect for 40 years old. Here's what it started out as:
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_Start_01_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_Start_02_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_Start_04_o.jpg
Again, rotten foam.
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_Start_05_o.jpg
Once the leather edgeroll and interior foam was removed, I went to work with the razor blade removing old, brittle reflective tape.
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_02_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_01_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_03_o.jpg
Then some holes were filled.
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_04_o.jpg
Primered and painted.
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_05_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_06_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_07_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_10_o.jpg
As mentioned with the Maverick helmet images, I taped the Goose visor at the same time. For the Eagle on the Goose helmet, my buddy didn't have any blue vinyl, so we used black car wrap (which he did have). This stuff is great as it's a bit stretchy and air bubbles just push out so easier to use than the vinyl.
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_12_o.jpg
Again, the white parts of the eagles don't meet. This was how far I took the helmet for the party as I ran out of time. Eventually I intend to finish the reflective tape at which point you'll no longer see any of the black. Also, note the preexisting damage on the back of the visor cover. I figured this was suitable for "dead goose." I have actually purchased a brand new HGU-33 visor cover that I intend on taping up for an undamaged version as well.
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_13_o.jpg
http://payload218.cargocollective.com/1/1/48431/6667604/GooseHelmet_WIP_14_o.jpg

Hi there- where did you learn to sew on the edge roll? I've been looking for instructions for an edge roll kit I purchased- did you learn it on your own?
thanks,
Jeremy
 
Hi Jeremy, I guess you would say I did just learn it on my own. I used a similar sewing pattern that I learned while making some of my leather props and holsters. I'd say a good place to start is by checking out leather awls, through that you should be able to find some simple sewing instructions online. I used my leather awl for this (though you could just use a needle), because I wanted to use the heavier awl thread. I basically used the technique in this linked image, but doubled up the pattern (so went one direction to the end, then doubled back over it to the start before tying off).

sewing_awl1.jpg

Hopefully that helps and good luck.
 
Hi Jeremy, I guess you would say I did just learn it on my own. I used a similar sewing pattern that I learned while making some of my leather props and holsters. I'd say a good place to start is by checking out leather awls, through that you should be able to find some simple sewing instructions online. I used my leather awl for this (though you could just use a needle), because I wanted to use the heavier awl thread. I basically used the technique in this linked image, but doubled up the pattern (so went one direction to the end, then doubled back over it to the start before tying off).

View attachment 270888

Hopefully that helps and good luck.

Thanks so much for your advice- it is much appreciated! I'll check out awls tomorrow. BTW- did you measure the hole you drilled for the thread or did you do it by eye? There is precious little material that I could find on installing an edge roll on an hgu-33. The guy I purchased the kit from sent me pics but I lost them when my computer crashed. Thanks so much again:)
Jeremy
 
This is SO awesome!!! I absolutely love Top Gun, so it's fantastic to see somebody go above and beyond like this. The helmets are killer, not to mention you both look like the actors! Really seals the deal. Stellar work all-around! :cool :thumbsup
 
Hi guys,
I am about to try to sew on my leather edge roll for my hgu-33 helmet- there are 4 leather pieces: two longer ones for each side and two for the front and back. Anyone have a picture of their leather pieces before sewing on labelled? I'd rather not guess.
Thanks,
Jeremy
 
Hi Jeremy,

Only pictures I took are the ones above I posted of my build. The one picture showing the new edge roll I cut out: The smaller of the two pieces is the one that goes on the back side of the helmet. I didn't have much to go off of, other than the old moldy leather bits I was replacing, so mine might not be the same as your.

I'd suggest test fitting them with the foam in place. If it seams like the leather bit will wrap around everything the right way just using your fingers to hold it in place, you're probably on the right track. Spin stuff around to be sure it doesn't work better another way.

Remember also, that the front and back should wrap over the side ends when you go to roll it over the foam. And that the ends of all the parts share stitches. So when you're first sewing them on, the front and back pieces go down first and then the sides.

Good luck and let us know how it turns out.
 
Thanks for the tips- that gives me something to go on:). I'll move stuff around until it looks like there is some kind of intelligent design behind it. I'll let you know how it goes- thanks again for being such a good source of intel!
Jeremy
 
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