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  1. RPF Premium Member canister's Avatar
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    Oct 26, 2016, 2:24 AM - Re: Rogue One Rebel Soldier Helmet #176

    Even these are a new shape even thogh they look similar to the endor helmets, was scouring the rebel legion forum for info on the poster helmet.

    What about canvas for the cover? thats looks like a good option too.

    wow great link there Simthjohnj!

    Awesome Halliwax, Even a plastic one for the 2nd one would work great I guess.
    Last edited by canister; Oct 26, 2016 at 2:37 AM.
  2. division 6's Avatar
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    Oct 26, 2016, 9:38 AM - Re: Rogue One Rebel Soldier Helmet #177

    The cloth cover is just that, cloth.
    Most helmets come with covers or you can buy one.
    Try to match the material.

    Instead of trying to cut up a helmet for your mold (good luck with that) cover the helmet with plastic wrap, place the outer shell on top then clay the edge's so there is no leakage.
    You can get non sulfur Plasticine (oil based clay) at just about any art store including Michael's.
  3. division 6's Avatar
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    Oct 26, 2016, 9:48 AM - Re: Rogue One Rebel Soldier Helmet #178

    When I did the side light for my nieces Rey costume I cast the mold inside some tubing then once molded cut the tubing open to use as the mother mold using rubber bands to keep it tight when casting.
    Since you will probably be hollow casting you may have to make the mold with removable plug center (2 piece mold) or have a greased tubing to drip in.
    The finger of a latex glove over it with a bit of Vaseline should work.
  4. RPF Premium Member canister's Avatar
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    Oct 26, 2016, 2:19 PM - Re: Rogue One Rebel Soldier Helmet #179

    Thanks Division IM guessing something like this
  5. halliwax's Avatar
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    Oct 26, 2016, 6:35 PM - Re: Rogue One Rebel Soldier Helmet #180

    division 6 said: View Post
    When I did the side light for my nieces Rey costume I cast the mold inside some tubing then once molded cut the tubing open to use as the mother mold using rubber bands to keep it tight when casting.
    Since you will probably be hollow casting you may have to make the mold with removable plug center (2 piece mold) or have a greased tubing to drip in.
    The finger of a latex glove over it with a bit of Vaseline should work.
    canister said: View Post
    Thanks Division IM guessing something like this
    https://www.youtube.com/watch?v=jkzFOFzQtp8
    division what do you think of that video. honestly i was watching a bunch of his videos last night. I've never cast a object of this size before. i was planing on going the route like the video, making the mold the exact way. i was going to use free form air, but im thinking by the time i buy the FFA, then fiberglass over it i might as well just go with the paste in the video.
  6. division 6's Avatar
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    Oct 26, 2016, 8:03 PM - Re: Rogue One Rebel Soldier Helmet #181

    It should work.
    I'm used to the fiberglass mother molds.

    From some projects my costuming group has done in the past, we went the more traditional route like in this video.

    The up side of the brush on silicon is getting in all the detail areas so there isn't any bubbles in the mold.
    The down side is having to keep brushing more on over hours, pour in version is pretty much one or 2 pours and your done.
  7. division 6's Avatar
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    Oct 26, 2016, 8:33 PM - Re: Rogue One Rebel Soldier Helmet #182

    If you plan to slosh cast then maybe something more like this will work.
    Click image for larger version. 

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    Having the inside more hollow so you only have to cast the outer edges.

    Or you could just do a 2 part mold (inside & outside) and solid cast them.
  8. halliwax's Avatar
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    Oct 26, 2016, 10:12 PM - Re: Rogue One Rebel Soldier Helmet #183

    division 6 said: View Post
    If you plan to slosh cast then maybe something more like this will work.
    Click image for larger version. 

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    Having the inside more hollow so you only have to cast the outer edges.

    Or you could just do a 2 part mold (inside & outside) and solid cast them.
    exactly what i was planning at first. but with your diagram, the hollow area, do you fill that with as well, to block off the top? i was just thinking that would be a lot of clay and cost a lot more money. i was debating on finding something like a bowl, to shove in the hollow area then use clay to fill the gap between the dome shield and the bowl. i was even thinking of sacrificing a M1 helmet just to fill the hollow area, but then got to thinking of finding some kind of Tupperware bowl

    i really appreciate your advice!
  9. division 6's Avatar
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    Oct 26, 2016, 10:22 PM - Re: Rogue One Rebel Soldier Helmet #184

    Think of a bunt cake pan.
  10. halliwax's Avatar
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    Oct 26, 2016, 10:27 PM - Re: Rogue One Rebel Soldier Helmet #185



    hmmmmm... thinking. i still cant visualize but im am still thinking
  11. halliwax's Avatar
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    Oct 26, 2016, 10:32 PM - Re: Rogue One Rebel Soldier Helmet #186

    here's a quick sketch of what i was thinking




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  12. halliwax's Avatar
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    Oct 26, 2016, 10:33 PM - Re: Rogue One Rebel Soldier Helmet #187

    the tupperware container would be upside down, simulating the curved shape of the m1 helmet. i could fill that whole thing with clay but that would be a lot of money in clay.


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  13. halliwax's Avatar
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    Oct 26, 2016, 10:37 PM - Re: Rogue One Rebel Soldier Helmet #188

    i would also do a 2 piece mother mold, i would try to keep the rebound 25 in 1 piece, depends i think the dome shield will have enough shape to pull out without ripping. basically something like this. i would prefer to keep the silicone mold 1 piece but we shall see

  14. division 6's Avatar
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    Oct 26, 2016, 11:29 PM - Re: Rogue One Rebel Soldier Helmet #189

    Still trying to think of a way to avoid wasting material on the casting side.

    If you do mold it with the M1 inside, do a single open face (with mother mold) then you could just pour resin in then place a greased helmet inside pushing the resin up the sides and leaving it hollow cast for the most part.

    Once cured just remove the M1 then remove the mold from the mother and pull out the resin copy.
  15. division 6's Avatar
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    Oct 26, 2016, 11:34 PM - Re: Rogue One Rebel Soldier Helmet #190

    With the original idea I posted (bunt pan like shape) the cone would go through the middle so less material is used.
    No need for the tupperware bowl.
  16. division 6's Avatar
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    Oct 27, 2016, 12:02 AM - Re: Rogue One Rebel Soldier Helmet #191

    Quick sketch of the indented mold.
    Click image for larger version. 

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  17. RPF Premium Member canister's Avatar
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    Oct 27, 2016, 1:39 AM - Re: Rogue One Rebel Soldier Helmet #192

    All these plans look awesome will throw this in the mix too, how bout roto casting it?
  18. Member Since
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    Oct 27, 2016, 7:44 AM - Re: Rogue One Rebel Soldier Helmet #193

    Ah-hah! Yeah! But there isn't only one poster!
  19. halliwax's Avatar
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    Oct 27, 2016, 8:22 AM - Re: Rogue One Rebel Soldier Helmet #194

    canister said: View Post
    All these plans look awesome will throw this in the mix too, how bout roto casting it?
    that's my goal, i don't have the tools right now to do it otherwise. i'm practically starting all over.

    these will be roto cast, also known as slush casting


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  20. Reelo's Avatar
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    Oct 27, 2016, 8:28 AM - Re: Rogue One Rebel Soldier Helmet #195

    Just chiming in so I have quick access to this thread later on. Very interesting. An M1 helmet is probably a lot easier and cheaper to get (also iirc there are NATO variants from different countries available) than the WWII thing used for the donut helmet in RotJ. So it might be within my reach to actually build one (even if not a screen-accurate replica)
    I was wondering if the shield assembly could not be directly handcrafted from styrodur (hard construction foam) or cosplayflex or any of those fancy new materials. Might be easier, but who am I to know.

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  21. RPF Premium Member PropReplicator2's Avatar
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    Oct 27, 2016, 9:53 AM - Re: Rogue One Rebel Soldier Helmet #196

    Reelo said: View Post
    Just chiming in so I have quick access to this thread later on. Very interesting. An M1 helmet is probably a lot easier and cheaper to get (also iirc there are NATO variants from different countries available) than the WWII thing used for the donut helmet in RotJ. So it might be within my reach to actually build one (even if not a screen-accurate replica)
    I was wondering if the shield assembly could not be directly handcrafted from styrodur (hard construction foam) or cosplayflex or any of those fancy new materials. Might be easier, but who am I to know.

    Sent from my Nexus 6P using Tapatalk
    Yes maybe, but it would suck to mass producw them like that.

    Alex
  22. Reelo's Avatar
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    Oct 27, 2016, 9:56 AM - Re: Rogue One Rebel Soldier Helmet #197

    alexmiller1 said: View Post
    Yes maybe, but it would suck to mass producw them like that.

    Alex
    Not for mass-production. For production of a master which could *then* be used to create a mould for mass-production. Maybe more efficient than to try and mould around a full helmet first.

    Sent from my Nexus 6P using Tapatalk
  23. RPF Premium Member PropReplicator2's Avatar
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    Oct 27, 2016, 9:59 AM - Re: Rogue One Rebel Soldier Helmet #198

    Reelo said: View Post
    Not for mass-production. For production of a master which could *then* be used to create a mould for mass-production. Maybe more efficient than to try and mould around a full helmet first.

    Sent from my Nexus 6P using Tapatalk
    Oh ok misunderstood then. I thought you meant makr everyones individually by hand.

    Alex
  24. rundown's Avatar
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    Oct 27, 2016, 12:52 PM - Re: Rogue One Rebel Soldier Helmet #199

    The rubber band is defenitly a "weight lifting rubber band" or "resistance band"

  25. Member Since
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    Oct 27, 2016, 2:16 PM - Re: Rogue One Rebel Soldier Helmet #200

    The outer layer of the helmet reminds me alot of a 1970s Cooper SK 600 hockey helmet maybe used that as a base of its molds and concepts.
    Click image for larger version. 

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    Click image for larger version. 

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