How do you make a Lego mega-figure helmet?

[rocketboy314]

Hello RPF, long time listener, first time caller.

As a kid I built many (many!) model airplanes/star ships/aircraft carriers...etc. Now that my children are out of diapers, I am looking to get back into it.

Looking through this forum, I saw a couple of threads in which craftsmen built Lego mini figures and had to have one. This spring, I built one of my own, a 20:1 scale model. I consider it a great experience, learned a lot, and is a great way to relieve stress.

The mega-figure was pretty straight forward in that it is mostly straight lines and circles. This paint scheme is a Speeder Bike Scout Trooper.

I would really like to build a helmet, however, I have no idea on how to get the correct dimensions/shape.

One thought was to purchase a dozen or so 'extra' Lego helmets, embed them in epoxy (or other) and then slice them down to create scaled templates that could then be re-stacked in MDF. Anyone ever tried this? Other ideas? An 8' PVC coupler fits over the head nearly perfectly, but then how would you capture the curve of the outer surface (top-to-bottom) and create the visor? Anyone know where I can get a slice-able 3D rendering?

Any tips/tricks would be greatly appreciated,
Brian


I made a board with a bolt set back from the table saw cut to make the head/hands OD; used an adjustable hole cutter for the inside ID.


I used fiberboard and spray polyurethane foam for the arms. Don't do this. The fiberboard can get wet and come apart. Certainly don't forget to inset a bolt or other for attaching them to the body (I did). The arms fit a couple of rectangles and the forearms are circular.

0.020" polystyrene sheet covers the head and the hips/back of the legs. Belt sander works great for shaping the hands.

Technically, he should have a solid black head. Where is the fun in that?

 

[Junk Pilot]

That is so friggin awesome. It looks great.

What about using a block of styrofoam? It's easy to cut and shape and would be lightweight.

 

[Strode]

That's really cool!

 

[funboy1013xx]

you could use pictures of a speeder bike helmet front/sides/back have them enlarged at a printing shop or at home if its within your paper size. and then sculpt etc. looks great so far!

 

[laellee]

I modded a traditional Iron Man helmet to fit for my Lego suit, modding the dimensions to fit the lego head properly:



If you know how to use Pepakura, I can probably throw together a file during the day tomorrow that you could use as a template for the Biker Helmet (I already have a couple of models to work with here). I would just need dimensions of the head including heights and diameters of the sections (neck, main head, top post). I'm already working with my Lego stuff, so it wouldn't be a problem.

 

[rocketboy314]

Thanks Junk Pilot and Strode. What material would be best to use, funboy1013xx?
laellee, that would be awesome! I don't know how to use the software, but will figure it out. The top post od is 3.75", head diameter is 7.8", bottom post od is 5". The height for each of these respectively are 1.56", 6.7" and 0.825".

 

[laellee]

Cool, just send me the dimensions of your lego head and I'll get something to you.

 

[funboy1013xx]

you can use flower foam, it comes in different sized circles, balls and blocks (like lego's!) and hot glue them together. and then use sand paper to shape. its messy but its cheap! I used it to sculpt an alien head then covered it with plasticote spray. other members might have an easier idea.