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New PGHFETT Helmet


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OK guys...

This is what we did to get the helmet up to par with PGHFETT's original helmet. We had to make some minor adjustments, the molds were old and worn out so the pull came out a little off. Well lets say we took the helmet and made it look like Mike did, just like the E3 Bark Trooper.

 

Once we were able make a pull from the original molds, we got started...

 

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Went from here we had to plarmaturearmetru ( a pole inside the bucket to make it easier to make the MOLD in the end.

 

Sand it down to perfection, then began to do some Bondo work to add some of the detail lost in transition.

had to line up and make sure all angles were up to par...

below are some of the pictures...

 

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Primer it with a dark gray primer. Whenm Im working on a master, I like to use dark, light and red primers, spray one coat of the dark primer and sand it down to where I feel the helmet is smooth. Then I apply the light gray so why I sand again, the contrast from the two colors come up and I can see where Bondo is needed, and where I need to remove some of the excess Bondo... go back and forth with the different colors till Im happy with the finish product.

 

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At this point the helmet is taking shape...

 

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I have a bunch of pictures and cant find more, but once we had the helmet where we felt it looked like the original we went off the the Molding table.

 

Next is a quick process on making the mold for this helmet...

 

 

 

 

 

 

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Molding the helmet... YES ITS A CUT AND PASE FROM ANOTHER SITE lol

 

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First off set your master on a silhouette cut out of your piece then place almost level with the cut out.

 

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Glue sticks close to your master closing out the opening you have.

 

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With clay you will have to build a level FLAT area, this will be the dividing wall between the two halves. Over the flat sheet, cover the entire sculpt with 3/8 to ½ inch sheet of clay.

 

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Add the keys on the top of the mold and the last key on the outer part of the mold. The keys is what will keep the silicone from moving around or falling off the jacket.

 

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Once that is done, add a total of 3 coats of bondo resin with a 2 inch brush, take your time and make sure that by the third coat you the entire clay covered with the bondo resin.

 

Then cover with 3 coats of fiberglass.

 

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Here is the thing this part will take about 4 to 5 hours once it's done, you have to leave it to cool off and guess what repeat the same on the other side lol...

 

Flip the mold over, this time you don't need the wood cut out, the flat area of the fiver resin is your working table so DON'T make another clay flat area, work directly on top of the resin table. see...

 

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See repeat all the steps and...

 

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To answer any questions this process does take a long time, you cant rush it as the materials used do generate heat and that is how they cure so the complete process to ensure a great mold is to do it in 4 to 5 days.

 

Day one 4 to 5 hours make once side of the jacket with the clay.

Day two 4 to 5 hours make the other side of the jacket.

 

Quick FYI you can do this all in two days, but you do take a rick that the chemicals will harden faster on the second half due to the heat the first half generated for several hours after molding. So it's best to take your time. For those that work with resins and bondo know that heat is the key factor in the catalyst of the chemicals. to much heat will make them gel up faster.

 

 

NOW

after all the work is done, yoe get this...

 

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  • 1 month later...

Thank you guys. I like swing things come together we started this and I'm just glad it's finally moving. Here are some pictures of the armor :).

 

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What material is the armor going be made of?

The helmet looks great!

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  • 3 weeks later...

please dear god finish the armor and start offering kits. i have been making KT armor for 3 years and i want to resculpt parts but can't until i get done with orders. plus i would like people to have a choice on KT armor.

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  • 6 months later...
  • 9 months later...

A kind of dumb question to ask on these forums is does the kashyyyk scouts visor flip up like the biker?ik it does on the action figure but I'm not sure bout the real thing

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  • 11 months later...

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