Tjeccles's Armor Build.

[Tjeccles]

So I'm finally getting the armor out of the box and working with it. The armor I have is CFO/Strider's armor.

 

The TD was on top so I figured I'd start with that. The caps need to be cut.

 

What size are the caps supposed to be? Are they 1/2 inch?

[Chopper]

Here's a photo of the original screen used caps. 

I'd say the measurements are about 3/8" to 1/2".

[Tjeccles]

Thanks Chopper.

[sskunky]

Any updates? 

[Tjeccles]

Any updates? 

I unexpectedly got a job in China for a year so I have been unable to work on anything.

[sskunky]

Good news for work and bad news for building.  

[Tjeccles]

Good news for work and bad news for building.  

I agree and I didn't really want to try and bring it with me to work on.

[Tjeccles]

So my build hiatus can finally end. I figured I would start on getting the bucket done since I have most of what I need to finish that while I work on getting some money.

Quick question: Is this the chin cup?

I have the Lonewolf bucket that Mark did and it's the only part I'm not sure on.

 

[Chopper]

Yes indeed, that is the chin cup!

[Tjeccles]

On the first picture, do I need to trim more off or is that good?

On the second picture, the black line is where the lip from the casting is. What is the best way to cut that, using a Dremel or lexan scissors?

[Chopper]

Your trim lines look good. 👍

Either will work. I personally prefer lexan scissors for most of my trimming, then I file down the rough parts with a heavy duty emory board.

[Tjeccles]

Your trim lines look good.
Either will work. I personally prefer lexan scissors for most of my trimming, then I file down the rough parts with a heavy duty emory board.

On the front, should I trim down to the black line or leave it? I don't want to trim too much off.

[Chopper]

You can trim down to your marked trim lines on the helmet. You should leave a return edge, but your marked lines look ok.

Here's a few photos of one of the original helmets. You can use that as a reference:

[Tjeccles]

Rough cut for the bucket is done. I'll work on the visor and faceplate tomorrow.

[sskunky]

Looking good. Glad to see you back at it.


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[sskunky]

I built some helmets lately. They do look nice once finished.


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[Tjeccles]

I have one piece completely cut out! Granted it's the chin cup but it's still something.

I have the back side and bottom cut on the visor pieces. I'm going to get some help from a Garrison mate with the top and front.

[Tjeccles]

I have my ear holes cut out and my faceplate started. Except for sanding, do my ear holes look good? I tried to stay right on wear the plastic started to curve. I figure need to take another 2-3 mm off on the faceplate before sanding

[Chopper]

 

Looks like a decent start on the ears, but you could trim them out a bit more. 

Here's some more reference photos of the screen helmet that should help. 

[Tjeccles]

Thanks Chopper

[Tjeccles]

Trimmed my visor and ear holes some more. Also started on joining the two halves together. I used Loctite super glue to attach the pieces to the bucket. After those dry, I know I need to use Bondo to fill the gap. Is this stuff good or is there something that works better?

[greenyone]

Just my 2 cents.

Bondo (or any body filler for that matter) are going to be the easiest to sand and shape, but I'd guess a 2 part plastic epoxy (similar to the one you pictured above) would be a stronger gap filler and be less prone to cracking when dry.  Not to mention that stuff is specifically made to adhere to plastics.  You can still use a thin coat of bondo to smooth things out though.  If you can find the 2 part plastic epoxy in white it may make your life easier when it comes to paint coverage though.

[sskunky]

 the best way to join these I’ve found is to brace the parts with strips of abs on the inside of the join and stick together with a liquid solvent cement whilst clamped in position. . Once that’s set fill the gap with a abs paste made of scrap bits of abs and the liquid solvent cement. Leave that to set overnight and sand smooth. I then pretty much cover the whole top of the helmet with a plastic bumper filler which is slightly flexible. And as much over the back seam that is permitting. Sand that smooth and a paint with a filler primer and make good. Than you can top coat. 

[Tjeccles]

What is the best way to trim the visor pieces to the right size? Do people make a cardboard stencil? My eyeballing skills aren't the best

[greenyone]

A lot of helmets come with trim lines kinda molded into the plastic.  I'd guess if yours does not you are going to have to improvise.  Maybe put some painters tape along that edge and free-hand it in pencil...erase if necessary and repeat until it looks nice an uniform.  Whatever you do, I'd prob cut on the outside of your line (leave a little extra plastic than you intend to have when finished), then slowly and carefully sand it down into the desired shape.