Rebel Trooper Helmet

[TatooineMachine]

I had to fill the original holes on the pre visor - taped the front and used JB Weld. You could see the holes through the new tinted visor and we can't have that!

A little spot putty, primer and paint and they will vanish!

 

[Inquisitor Peregrinus]

I'm having to do that with my Tambo Imperial version of this helmet. He went with a warts'n'all slap-dash approach replicating the original assembly. Mold damage, not perfectly aligned or spaced holes, roughout texture on the main bucket, prototype earcaps, etc. I've had to back off, fill, and smooth a lot of holes. I also have an original "talker" helmet I put the main portion of the plastic helmet in to push it into the right shape, and epoxied a craft ring into it to hold that shape against the outward pull of the add-on pieces.

I love how there's no such thing for us as an "out of the box" kit. We always have to improve it.

 

[TatooineMachine]

Finally got the paint where I want it. Gloss white is a PITA! I ended up using satin white with clear gloss over the top, much easier job! Messy work bench with my R5-D4! I'm off to get screws for the visors and assemble the pre-visor & face shield. The new rear swoop is in the mail from Texas and I hope to get it tomorrow....

 

[Inquisitor Peregrinus]

My preferred simple gloss finish is RustOleum's Professional Grade black or white. They have ground up ABS dissolved in suspension, so once it cures it's like polished plastic. Here's a Scout helmet I did with it:

Looking good, though. Can't wait to see things come together.

 

[russellsch]

Can't wait to see this baby all finished!

 

[TatooineMachine]

Chamfered the holes on the visor for pan head screws

Screws fit flush - used nylon spacers between the visor and pre visor, then pre visor to helmet too

Assembled

 

[kev1969]

Wow, what a great build.. watching.. and very tempted to buy a kit myself.

 

[russellsch]

Come on rear swoop!

 

[TatooineMachine]

Come on rear swoop!

Monday! I’ll add the strap & chin cup, paint the visor screws one light coat w a brush so hopefully it matches the visor a little better. While I wait for the rear swoop I’ll work on making the com-box more screen accurate so I can paint it up with the swoop. I’m happy with how it’s coming out

 

[TatooineMachine]

Chin cup and strap added

 

[Pedro]

Love this! Really nice work on an under-attempted helmet. This one always scares the crap out of me when I ponder making it. The lines are all so vague...where the heck do you cut??? Yours looks perfect!

 

[russellsch]

Love this! Really nice work on an under-attempted helmet. This one always scares the crap out of me when I ponder making it. The lines are all so vague...where the heck do you cut??? Yours looks perfect!

I completely agree. & every photo update is better than the last. I can't wait for you to receive the back swoop. When you finish this piece, I know it will be perfection.

 

[Halliwax]

Really outstanding!

 

[TatooineMachine]

Rear swoop came in yesterday. I’ve decided that the tinted visor needs some adjustment - it’s not symmetrical to the pre visor. A little work on the table sander and it’ll be perfect. I’m going to make a template of the rear swoop and make sure it’s also symmetrical in shape, trim it up if needed, and paint it! Then the com box and we’re in business! More to come

 

[TatooineMachine]

Fixed the unsymmetrical arch on the tinted visor, it now lines up well with the pre visor.

 

[TatooineMachine]

Made center masking guides on the visors

Then the swoop

Drilled holes and mounted the swoop

Need to paint the swoop and clear it, pop rivet the chin strap onto the helmet liner, and start on the com box....I'm pretty happy with it so far

 

[russellsch]

This is officially a dangerous thread for me now. This amazing build is making me want one.

 

[TatooineMachine]

I finally got a good base coat of satin white on the swoop, I’ll wait a few days and clear it! I’m going to work on the combox this afternoon and try and get it ready for filler.....

 

[TatooineMachine]

Made some good progress on the combox

The vac formed piece in the kit has the ridges on the right side as raised but the screen and costume book pics show indented lines. I felt the top buttons are too vac formed looking and the dishwasher thermostat didn't have enough detail to be accurate. I'll swing by the shop cut the grooves with a pen router and use the spindle sander to arch the backside to fit the helmet and add the details, then I can putty and prime!

 

[TatooineMachine]

Swoop progress

Still need to do the combox....