Kylo Ren Black Series Helmet Mod

NeoRutty said:

That's awesome... Did you use something fancy to cut the aluminum? I've thought of re-building the mouth piece myself, but wasn't sure what to do it out of. That looks great, but my tools are minimal.

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event said:

Thanks for the compliments.

I just score with a razor blade (I use a nicer box cutter) and then bend at the seams till they split. I slowly work the pieces back and forth till they give. For straight lines I might speed things up with some scissors and I use pliers where I can to keep things from warping as I split the seams. Flatten unwanted warping with whatever I have laying around that's flat or cylindrical that can smash, slide or roll over the warp. Deburr with metal files and finish with sandpaper.

Honestly aluminum is very forgiving and you can get some really clean lines, much cleaner that you could with sintra, styrene and the like.

Click to expand...

event said:

Thanks for the compliments.

I just score with a razor blade (I use a nicer box cutter) and then bend at the seams till they split. I slowly work the pieces back and forth till they give. For straight lines I might speed things up with some scissors and I use pliers where I can to keep things from warping as I split the seams. Flatten unwanted warping with whatever I have laying around that's flat or cylindrical that can smash, slide or roll over the warp. Deburr with metal files and finish with sandpaper.

Honestly aluminum is very forgiving and you can get some really clean lines, much cleaner that you could with sintra, styrene and the like.

Click to expand...

NeoRutty said:

How thick is the aluminum you're using?

Click to expand...