Lineage Return of The Jedi Darth Vader Production Made Helmet
“Bob Rose” BR Vader ROTJ version
The following post will detail the provenance of our linage Darth Vader helmet soon to be available in a limited 2024 / 2025 run, a lineage Darth Vader Helmet originally made by our uncle “Bob Rose” who worked on Return of The Jedi.
These Vader replicas once complete are two molding generations down from the “BR” production made casting made during the production of ROTJ. These came from the “UK Mold” of the face plate and a ROTJ era Dome Mold.
So, for extra clarification the "UK Mold" was made sometime after ANH was released and when ESB started filming and is the Mold set used to cast the faceplate and dome castings that became the screen used ESB helmets.
So, the ESB helmets were one molding generation down from the original ANH helmet. The helmets used in ROTJ either were refurbished ESB helmets or potentially new helmets consisting of faceplate castings from the "UK Mold" that were modified in some ROTJ specific ways and a new dome Mold that was also unique to ROTJ. Our uncle's casting is the latter; a new pull of the faceplate from the "UK mold" and a pull from the ROTJ specific dome mold.
This is not a mass-produced collectable; it is a hand-made prop re-created by us in the same spirit as the originals seen on screen.
Every detail from this iconic Darth Vader helmet has been carefully captured to recreate a near as perfect ROTJ true linage replica.
Each replica helmet will come with a limited-edition plaque and employ imbedded identification NFC technology in both the mask and dome.
Each helmet is finished by hand and painted to represent as best possible an accurate “ROTJ” look using Rolls Royce paints and custom machined aluminum tusks and aluminum expanded mesh.
The following set of pictures below are renders from Alexander Stojanov using digital assets we supplied to him from the multiple comprehensive scans we commissioned of the production made “BR” Darth Vader helmet.
Both traditional and modern methods are used to bring this lineage helmet to reality.
It’s important to us to say from the very off that initially we never planned to make no more than 4 cast’s just for us in the family us “cousins” that have always wanted copy of “BR” Bob Rose (Uncle Bobs) Vader all our adult lives.
Our family has a long and deep routed family connection to the Star Wars trilogy and the movie industry spanning fifty plus years till the present day.
So, for as long as we can remember Vader has always been around, I used to see him every summer when me and my brothers went to visit my Aunty and Uncle in London as a child. He didn’t scare us when we used to watch him in Star Wars and used to think he’s not that scary? he’s upstairs on the bookshelf?
If he was that strong in the force he’d come get his helmet, wouldn’t he?
In fact, I’ll play with his helmet in the back garden pretend I’m him playing Star Wars………if he wants it, he can come get it “take that Vader”.
Yes, we used to play with this helmet in the garden all summer we can only apologize for our crimes against prop culture and history.
What we didn’t realize while we were all running round the house and garden like Darth Vader and playing with the baby Ewok puppet from Jedi was that “Uncle Bob” worked in the film industry and some family still do at the studios in the UK to the present day.
Unfortunately, the Ewok succumbed to the ravishes of time many years ago but was great to play with as a kid………I know don’t say it.
Throughout his career “BR” worked on 100’s of movies right up until his unexpected time of passing and one of these movies was Return of The Jedi.
On Jedi “BR” our uncle worked alongside Stuart Freeborn in his workshop, and we would regularly go down during production and sit in there while the guys were making Jabba and all the other wonderful stuff.
Call Sheet from ROTJ
Above is a photo of one of my cousins in the workshop holding a Yoda head. He said that it was in a bin. This is one of many family photos we have and are happy to share here as we know this one is already out there in the world. (He didn’t keep the Yoda cast)
So, during the production of Jedi “1982 “BR” cast this Vader faceplate in Stuart Freeborn’s workshop,
Several versions of helmets were used during filming of Return of the jedi detailed write ups of these variations can be found here on the RPF and the Prop Den.
The tusks were part of the faceplate cast originally when “BR” made it, but they snapped off over the years. We have one tusk left but is not currently on the “BR” Vader helmet and decided not to reattach it during any of the process.
To him casting this iconic helmet at the time was like plastering a wall or changing a tire, it was just a day’s work but to the rest of us it would be a dream come true.
Below are the original photos we posted nearly two years ago on our face book feed.
This is not the first time that this helmet has been mentioned if you were to look back at the CFO thread on RPF you will see one of our family members mentioning the existence of the helmet in our family in 2016 / 17.
To start we initially needed hi resolution scans of “BR” helmet which we commissioned to be completed some pictures shown below.
From this data and help of Alexander an accurate Jedi era mount ring was created and accurately matched and placed correctly on both the mask and in the dome (we were able to digitally repair the areas of damage only, that were present on the faceplate) and from this we produced a prototype hi resolution helmet printed in black high impact durable resin the now named “BR prototype”.
While we were waiting for the prototype to be completed, we decided to mold the “BR” mask and dome. We used Rebound 25 silicone and all the platinum products from Smooth on to do this mold and all subsequent traditional molds.
Above shows the digitally repaired hi res 3d printed prototype on left / raw unprocessed 3d print center with prototype aluminum tusks / Gen 1 cast from BR mask mold which will become gen 2 jedi master faceplate cast.
So, for clarification the 3D scan mesh/3D print of the dome and mask wasn't used in the end as we opted to directly Mold the source BR casting, made the ROTJ specific modifications to this gen 1 casting from that BR Mold, then a Mold of this modified casting is used to produce the actual replicas on offer.
The following pictures show the mother mold being made of the “BR” faceplate and dome.
“BR” original faceplate on the left and the first pull from the mother mold on the right shown above.
Jedi Modifications Gen 1 cast
So, it was becoming clear now we had “OVD” Obsessive Vader Disorder, and we made the decision to make 20 true linage “BR” ROTJ Vader Helmets.
To do this, we studied and meticulously went over every reference picture privately shared with us and publicly available picture of the original face plate / past and present and began to physically restore the damaged areas on our 1st pull faceplate to make our “ROTJ Linage Face Plate master”.
Again, it’s important to note that only areas of deterioration / damage were restored all other lineage tells marks and such have been left unaltered. This was a very time-consuming part of the process and only exacerbated the OVD!
See Pictures below:
The last picture shows the Jedi Gen 1 master mounted center and mother mold left and first pull from this new ROTJ mold right Gen 2 cast and replica to be used for the offering.
Next step was to cast the dome so again the same approach was adopted create a Gen 1 master from the “BR” dome apply minor repairs and mount. This Gen 1 master from the BR was then used to produce the domes which we then had professionally vacuum cast.
The dome had only minor repairs done to some edging and all other linage tells marks are present in the final dome product.
Jedi Master / Run helmet / “BR” original Dome
Above shows: Jedi Mask cast / Dome and accurate dome mount ring picture above.
All the faceplates are roto cast by hand using Smooth on onyx fast / slow polyurethane. To that end each faceplate has a unique handmade interior finish.
Each dome and face plate will have imbedded serial numbers using NF (Near Field) technology which can be scanned by both android and iOS devices. These serials will be linked to the collector and the respective helmets components.
If the serials are copied / disclosed or don’t match each other as in dome and plate, then the integrity of that linked lineage Vader helmet becomes compromised. We have integrated markers and other features into each of these masks and domes which allow us to identify each individual helmet and thusly any recasting or nefarious activities best possible.
We don’t own Vader, but we are proud and protective of our uncles’ work and ours. And we hope that the fandom community respects this and the very personal family piece we have decided to share with all that wants to have a true lineage collectors' piece.
We will always be available to verify or check anything with one of our pieces.
Accurate Rolls Royce “J Mason” black and Rolls Royce Tudor grey paint will be used matched with their respective paint codes for the helmets as the original Jedi prop helmets.
We have produced and had custom made CNC aluminum tusks which are ROTJ movie accurate again thanks to the skill of Alexander using our scan data and references. Both large and small mesh / grills have also been matched and sourced for the helmets.
However please note that the “BR” prototype picture below which we have used as a paint test and assembly piece has the incorrect large mesh installed and the nose is not silver and is not representative of the final piece finish, we are hoping to execute.
Prototype in and outdoor images.
Prototype and run dome which is unpainted in this picture
When all 20 are complete subject to final pictures they will be available to buy / no reserving or deposits will be taken and to it make fair to all possible interested parties please register your interest to the email below and we will inform all when they will be up.
The final price is yet to be confirmed as the helmets are not complete and we are unsure of how much time and funds are needed to get the project complete and all other logistics are yet to be sorted and confirmed. We are happy to answer questions as best possible and they can also be directed to the email below.
Studiostaff1977@gmail.com
Thanks for reading and be gentle with us it’s our first project of this size and scale......but not the last lineage project. This post will be updated as we go so please follow.
Credit / Thanks
In no order:
The Vader community in general for the help sorry cant list all your names.
Mike Coutts / Jose Fernandez for sprinkles of Vader polish on this post.
Uncle Bob, we still miss you and the laughs you always gave us all.
“The Cousins” you know who you are you Star Wars mad set of lunatics.
CFO Mark Edwards for supplying the Jedi “Call Sheet” to us way back in the day and mesh help.
“Too much garlic” for your Vader expertise and scanner guru help.
And finally,
Alexsander Stojanov who without his contribution to this project means it would not have ever likely come to be, his knowledge and artistry in both the digital world and physical are second to none.
I cannot recommend his work highly enough and he is a gentleman of code which in modern times is few and far between.
Insert: gratuitous link to Alexanders pages and fantastic work.
https://www.artstation.com/alexander_stojanov
“Bob Rose” BR Vader ROTJ version
The following post will detail the provenance of our linage Darth Vader helmet soon to be available in a limited 2024 / 2025 run, a lineage Darth Vader Helmet originally made by our uncle “Bob Rose” who worked on Return of The Jedi.
These Vader replicas once complete are two molding generations down from the “BR” production made casting made during the production of ROTJ. These came from the “UK Mold” of the face plate and a ROTJ era Dome Mold.
So, for extra clarification the "UK Mold" was made sometime after ANH was released and when ESB started filming and is the Mold set used to cast the faceplate and dome castings that became the screen used ESB helmets.
So, the ESB helmets were one molding generation down from the original ANH helmet. The helmets used in ROTJ either were refurbished ESB helmets or potentially new helmets consisting of faceplate castings from the "UK Mold" that were modified in some ROTJ specific ways and a new dome Mold that was also unique to ROTJ. Our uncle's casting is the latter; a new pull of the faceplate from the "UK mold" and a pull from the ROTJ specific dome mold.
This is not a mass-produced collectable; it is a hand-made prop re-created by us in the same spirit as the originals seen on screen.
Every detail from this iconic Darth Vader helmet has been carefully captured to recreate a near as perfect ROTJ true linage replica.
Each replica helmet will come with a limited-edition plaque and employ imbedded identification NFC technology in both the mask and dome.
Each helmet is finished by hand and painted to represent as best possible an accurate “ROTJ” look using Rolls Royce paints and custom machined aluminum tusks and aluminum expanded mesh.
The following set of pictures below are renders from Alexander Stojanov using digital assets we supplied to him from the multiple comprehensive scans we commissioned of the production made “BR” Darth Vader helmet.
Both traditional and modern methods are used to bring this lineage helmet to reality.
It’s important to us to say from the very off that initially we never planned to make no more than 4 cast’s just for us in the family us “cousins” that have always wanted copy of “BR” Bob Rose (Uncle Bobs) Vader all our adult lives.
Our family has a long and deep routed family connection to the Star Wars trilogy and the movie industry spanning fifty plus years till the present day.
So, for as long as we can remember Vader has always been around, I used to see him every summer when me and my brothers went to visit my Aunty and Uncle in London as a child. He didn’t scare us when we used to watch him in Star Wars and used to think he’s not that scary? he’s upstairs on the bookshelf?
If he was that strong in the force he’d come get his helmet, wouldn’t he?
In fact, I’ll play with his helmet in the back garden pretend I’m him playing Star Wars………if he wants it, he can come get it “take that Vader”.
Yes, we used to play with this helmet in the garden all summer we can only apologize for our crimes against prop culture and history.
What we didn’t realize while we were all running round the house and garden like Darth Vader and playing with the baby Ewok puppet from Jedi was that “Uncle Bob” worked in the film industry and some family still do at the studios in the UK to the present day.
Unfortunately, the Ewok succumbed to the ravishes of time many years ago but was great to play with as a kid………I know don’t say it.
Throughout his career “BR” worked on 100’s of movies right up until his unexpected time of passing and one of these movies was Return of The Jedi.
On Jedi “BR” our uncle worked alongside Stuart Freeborn in his workshop, and we would regularly go down during production and sit in there while the guys were making Jabba and all the other wonderful stuff.
Call Sheet from ROTJ
Above is a photo of one of my cousins in the workshop holding a Yoda head. He said that it was in a bin. This is one of many family photos we have and are happy to share here as we know this one is already out there in the world. (He didn’t keep the Yoda cast)
So, during the production of Jedi “1982 “BR” cast this Vader faceplate in Stuart Freeborn’s workshop,
Several versions of helmets were used during filming of Return of the jedi detailed write ups of these variations can be found here on the RPF and the Prop Den.
The tusks were part of the faceplate cast originally when “BR” made it, but they snapped off over the years. We have one tusk left but is not currently on the “BR” Vader helmet and decided not to reattach it during any of the process.
To him casting this iconic helmet at the time was like plastering a wall or changing a tire, it was just a day’s work but to the rest of us it would be a dream come true.
Below are the original photos we posted nearly two years ago on our face book feed.
This is not the first time that this helmet has been mentioned if you were to look back at the CFO thread on RPF you will see one of our family members mentioning the existence of the helmet in our family in 2016 / 17.
To start we initially needed hi resolution scans of “BR” helmet which we commissioned to be completed some pictures shown below.
From this data and help of Alexander an accurate Jedi era mount ring was created and accurately matched and placed correctly on both the mask and in the dome (we were able to digitally repair the areas of damage only, that were present on the faceplate) and from this we produced a prototype hi resolution helmet printed in black high impact durable resin the now named “BR prototype”.
While we were waiting for the prototype to be completed, we decided to mold the “BR” mask and dome. We used Rebound 25 silicone and all the platinum products from Smooth on to do this mold and all subsequent traditional molds.
Above shows the digitally repaired hi res 3d printed prototype on left / raw unprocessed 3d print center with prototype aluminum tusks / Gen 1 cast from BR mask mold which will become gen 2 jedi master faceplate cast.
So, for clarification the 3D scan mesh/3D print of the dome and mask wasn't used in the end as we opted to directly Mold the source BR casting, made the ROTJ specific modifications to this gen 1 casting from that BR Mold, then a Mold of this modified casting is used to produce the actual replicas on offer.
The following pictures show the mother mold being made of the “BR” faceplate and dome.
“BR” original faceplate on the left and the first pull from the mother mold on the right shown above.
Jedi Modifications Gen 1 cast
So, it was becoming clear now we had “OVD” Obsessive Vader Disorder, and we made the decision to make 20 true linage “BR” ROTJ Vader Helmets.
To do this, we studied and meticulously went over every reference picture privately shared with us and publicly available picture of the original face plate / past and present and began to physically restore the damaged areas on our 1st pull faceplate to make our “ROTJ Linage Face Plate master”.
Again, it’s important to note that only areas of deterioration / damage were restored all other lineage tells marks and such have been left unaltered. This was a very time-consuming part of the process and only exacerbated the OVD!
See Pictures below:
The last picture shows the Jedi Gen 1 master mounted center and mother mold left and first pull from this new ROTJ mold right Gen 2 cast and replica to be used for the offering.
Next step was to cast the dome so again the same approach was adopted create a Gen 1 master from the “BR” dome apply minor repairs and mount. This Gen 1 master from the BR was then used to produce the domes which we then had professionally vacuum cast.
The dome had only minor repairs done to some edging and all other linage tells marks are present in the final dome product.
Jedi Master / Run helmet / “BR” original Dome
Above shows: Jedi Mask cast / Dome and accurate dome mount ring picture above.
All the faceplates are roto cast by hand using Smooth on onyx fast / slow polyurethane. To that end each faceplate has a unique handmade interior finish.
Each dome and face plate will have imbedded serial numbers using NF (Near Field) technology which can be scanned by both android and iOS devices. These serials will be linked to the collector and the respective helmets components.
If the serials are copied / disclosed or don’t match each other as in dome and plate, then the integrity of that linked lineage Vader helmet becomes compromised. We have integrated markers and other features into each of these masks and domes which allow us to identify each individual helmet and thusly any recasting or nefarious activities best possible.
We don’t own Vader, but we are proud and protective of our uncles’ work and ours. And we hope that the fandom community respects this and the very personal family piece we have decided to share with all that wants to have a true lineage collectors' piece.
We will always be available to verify or check anything with one of our pieces.
Accurate Rolls Royce “J Mason” black and Rolls Royce Tudor grey paint will be used matched with their respective paint codes for the helmets as the original Jedi prop helmets.
We have produced and had custom made CNC aluminum tusks which are ROTJ movie accurate again thanks to the skill of Alexander using our scan data and references. Both large and small mesh / grills have also been matched and sourced for the helmets.
However please note that the “BR” prototype picture below which we have used as a paint test and assembly piece has the incorrect large mesh installed and the nose is not silver and is not representative of the final piece finish, we are hoping to execute.
Prototype in and outdoor images.
Prototype and run dome which is unpainted in this picture
When all 20 are complete subject to final pictures they will be available to buy / no reserving or deposits will be taken and to it make fair to all possible interested parties please register your interest to the email below and we will inform all when they will be up.
The final price is yet to be confirmed as the helmets are not complete and we are unsure of how much time and funds are needed to get the project complete and all other logistics are yet to be sorted and confirmed. We are happy to answer questions as best possible and they can also be directed to the email below.
Studiostaff1977@gmail.com
Thanks for reading and be gentle with us it’s our first project of this size and scale......but not the last lineage project. This post will be updated as we go so please follow.
Credit / Thanks
In no order:
The Vader community in general for the help sorry cant list all your names.
Mike Coutts / Jose Fernandez for sprinkles of Vader polish on this post.
Uncle Bob, we still miss you and the laughs you always gave us all.
“The Cousins” you know who you are you Star Wars mad set of lunatics.
CFO Mark Edwards for supplying the Jedi “Call Sheet” to us way back in the day and mesh help.
“Too much garlic” for your Vader expertise and scanner guru help.
And finally,
Alexsander Stojanov who without his contribution to this project means it would not have ever likely come to be, his knowledge and artistry in both the digital world and physical are second to none.
I cannot recommend his work highly enough and he is a gentleman of code which in modern times is few and far between.
Insert: gratuitous link to Alexanders pages and fantastic work.
https://www.artstation.com/alexander_stojanov
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