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DFG Blaster Builders Club :: View topic - ANH Stunt Stormtrooper Helmet


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ANH Stunt Stormtrooper Helmet
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trooper96


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PostPosted: Fri Jul 11, 2014 5:56 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Repositioned the brow trim. I thought it was a little high in  the temple areas.





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PostPosted: Tue Sep 02, 2014 11:31 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

OK, now on to vacuum forming... I am going to tell you something you probably already know... Cloth and resin make a very poor mold material for vacuum forming. At least that was my experience. I had made a faceplate of paper mache sealed with resin and reinforced with resin and cloth on the inside. It seemed nice and sturdy. I tested the mold on the vacuum table with a thin plastic sheet (a test that had crushed a can earlier with just the pressure), and it held up. Next, I formed a faceplate using 0.063” black ABS material. I thought it turned out pretty good, though there were a few surface imperfections that needed to be worked out. After some rework and a second pull, I noticed that the mold was beginning to distort. Apparently, when heat is applied to resin, it gets soft. The face was beginning to sink under pressure in the area below the eyes to the cheek tubes. I am attempting to salvage the mold, as it took a long time to make, but it is starting to look like I will have to scrap it and start over with a better material. Down the drain, but not in vain... if you take into consideration that I learned something.

Here is the mold...


Here is the first pull...
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PostPosted: Wed Sep 03, 2014 5:51 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

excellent! sorry to hear about the distortion, but c'mon.. you knew you were taking a chance ;)

looking forward to seeing some serious vacu-formed stuff!
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PostPosted: Fri Sep 05, 2014 1:37 pm Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Click the link below to see the vacuum table in action...

https://www.youtube.com/watch?v=DaMcdcUiWuQ
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PostPosted: Tue Sep 09, 2014 9:46 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

How's my helmet and armor coming along? Wink
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PostPosted: Thu Sep 11, 2014 11:28 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Very Happy You may want to see how the whole suit comes out before you commission one.

Here's a few parts I have already trimmed up.


Here's me modeling the armor. The helmet is my paper mache project, not vacuum formed.


In full disclosure, my armor is derived from a suit of unknown origin, likely recast in my opinion. The quality of the suit was just OK. The details were a little soft in places, and the material (0.060" white styrene, nearly as I can tell) was very fragile. A friend of mine had come into possession of the suit and we saw an immediate need to improve it. He is one of those MacGyver types, so he built a vacuum form rig from materials he had in his shop. We made a few forming molds based on his suit. We built as many as possible from scratch, but we did end up making a few cement molds directly from the suit which required rework. We then purchased some 0.063” black ABS which I found available at a local Grainger store. Through some trial and error, we have managed to successfully make a few parts. The ABS material is many times tougher than the original. If you don't like the color, Rustoleum Universal Gloss White worked very well on a few test pieces we tried.

Stay tuned.
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PostPosted: Thu Sep 11, 2014 12:10 pm Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Wow, that turned out really good!!


Nick - ShadowBoss
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PostPosted: Thu Sep 11, 2014 6:04 pm Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Thanks!
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PostPosted: Fri Sep 12, 2014 5:52 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Great work!
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PostPosted: Mon Sep 22, 2014 5:56 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Here's a little more progress. Everything is coming along nicely. In addition to what you see here, we made a back plate, the rest of the thigh parts, the opposite forearm, drop boxes, ears, and a neck seal. We still need to work out the holster, knee bandolier, belt, some buttons and accessories for the ab and belt, face plate, and cap and back.



Then comes the fun part: trim, fit, assemble, paint and strap together. I also need boots and we are making flexible handguards from either white silicone or acrylic lates for the gloves. It would be very cool if we could get all of this done before Halloween!
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PostPosted: Mon Sep 22, 2014 8:17 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Excellent!
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PostPosted: Mon Sep 22, 2014 8:41 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Neck seal.



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PostPosted: Tue Sep 23, 2014 5:52 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

Ah yes.. to seal in all that sweaty goodness during those hot con days. Wink
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PostPosted: Tue Sep 23, 2014 6:32 am Post subject: No icon Re: ANH Stunt Stormtrooper Helmet Reply with quote

https://www.youtube.com/watch?v=mo3pIV1CLrQ
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