trooper1389 Posted October 4, 2011 Share Posted October 4, 2011 OK... I got the kit from Tim and Susie (BikerChick here on the boards) and I'm going to post up a Tutorial on how to work on this kit. First off the kit is made with a roto casting machine, that will greatly improve the quality of the bucket by spreading the casting resin evenly through out the mold and making it lighter and smooth inside. This WIP or how to work on the KASHYYYK helmet kit I hope will help out some of the old timers here and the new "B's" lol This is more of a set of instructions if any one here buys one of the kits. Feel free to PM me or http://forum.bikerscout.net/index.php?showuser=20517 biker chick for more information regarding one of the kits. Here is a picture of what the kit consist of. The kit should include the following... 1 helmet 1 visor 1 piece of lens 2 metal caps 2 sm pieces of screen or one large piece. 1 set of stickers 5 resin greebs 2 small risers FYI ( to rise the caps) 2 larger caps FYI..(go on top of the risers) 1 chin cover. STEP ONE First of like all other helmet made out of resin, once removed from package, inspect to ensure the kit does not have any shipping damage. Then go ahead and wash it with cold water and soap. let it dry completely. The purpose for this is to clean off any release agents sprayed on the mold for casting and by letting it sit for a week after is to ensure all gasses from the resin are gone. Resins are 2 part chemicals and do continue to smell (de gassing) for days after a helmet is made. So I let it sit till completely dry for a week or so, and I do let it sit in the sun for a few hours at a time to help it from de gassing. DON'T let it sit in the sun for an entire day as it WILL warp use common sense lol... Once dry, then you are ready to get dirty and begin your journey. STEP TWO 1. Inspect the bucket for any blemishes bumps that need sanding and dents or craters that MIGHT need a bondo filler. NOT saying the kit has bumps or craters as each bucket made is made with care, but from time to time depending on the climate, resins will do what they do with to much moisture or heat... So don't let this full you as the bumps and or craters might be 1/16 of an inch from air pockets for the craters, bumps from wear on the silicone molds. as you inspect, do so taking your time and with a pencil mark down all areas that need special attention. For this particular bucket, I had no areas that needed special attention to as it's the 3rd pull from the mold. 2. Sand down the entire bucket with good quality sand paper as you don't want the paper to fall apart on you. After you are done sanding, blow it clean and run your fingers all over the helmet to make sure you are free of any problem areas or if you find any problem areas, mark them with a pencil and re do step this step. At the same time, make pencil marks on the areas you know need to be cut out like the Visor / Lense mark down where you will be cutting off. Side vents... and make sure you clean the neck area good. Quote Link to comment Share on other sites More sharing options...
trooper1389 Posted October 4, 2011 Author Share Posted October 4, 2011 Tools needed to assemble and complete my helmet. Any kind of small hand held rotary tool (DREMEL is the one I use, here is the link for the site. http://www.dremel.co...l.aspx?pid=4000 4000 High Performance Rotary Tool make sure you get one that has various speed, and the best attachment is the #225 flex shaft http://www.dremel.com/en-us/Tools/Pages/ToolDetail.aspx?pid=225-01 . This tool will give you the ability to cut at various angles and tight areas. Also You will need cutting tools. For your major large cuts, I sue the #561 multi purpose cutting bit http://www.dremel.com/en-us/Accessories/Pages/ProductDetail.aspx?pid=561 . This will cut fast and accurate, just take your time as it will pull on you test it out first on scrap pieces of ABS or drywall. For sanding the areas after cutting, I use the #430 ¼ inch sanding drum http://www.etoolsrus.com/browse.cfm/4,4676.html and the #407 ½ inch sanding drum http://www.dremel.com/en-us/Tools/Pages/ToolDetail.aspx?pid=407 , depending on the area and size. This will give you a fine and smooth finish. DREMEL has numerous types of cutters and engraving bits, but the ones I mentioned are the most essential to use. Now to cut in tight areas, I use the X-ACTO No. 15 key hole saw. This is the same saw I use to cut out the face plate on the phase 1 and 2 helmet kits. http://www.xacto.com/Product/X215 You will need more than one trust me a few will be best, and take your time they bend easily. You will also need Sand paper various grits from rough to the finest you like to use. Pencil (for marking areas) CA glue (Flex-ZAP) Here are some hints how and where to use it http://www.zapglue.com/Hints/Flex.html and the glue http://www.shopwiki.com/Flex-Zap-Glue,1oz Also you can use the Kicker http://www.hobby-lobby.com/zap_kicker_2_oz._spray_2881_prd1.htm to harden the glue in seconds. This glue is also great for the armor. Hand tools needed... Files, small to large. Primer and paints. Dust mask for health reasons Bondo or any kind of filler Quote Link to comment Share on other sites More sharing options...
trooper1389 Posted October 4, 2011 Author Share Posted October 4, 2011 3. once you have the needed equipment, begin your journey... go ahead and cut them out. First off make sure you only cut close to the marked lines, NOT on the line as some of you know a rotary tool will zip in almost any direction so be careful and get as close as you can. and try it on 4. Once you have the parts cut out with the ZIP blade, with the 1/2 inch sanding drum begin to sand even closer. once that is done, using files you can clean up the areas as neat as possible or till your heart is content on the finished job. PICTURES TO FOLLOW!!! 5. If bondo or a filler was needed, make sure the entire helmet is sanded down do so and take your time. Once you have the bondo sanded down primer the kit . Repeat this step if you need to or until the helmet is 100% smooth. 6.. Re do step 4 and 5 once again to make sure the kit is 110% smooth now you should be happy and give it the final primer coat. ***** now the paint job on this helmet is hard I think but with in time I'll post up the rest of the WIP as I work on it. Quote Link to comment Share on other sites More sharing options...
trooper1389 Posted October 5, 2011 Author Share Posted October 5, 2011 OK I need some help the paint scheme and or colors... Gree is the Kashyyyk trooper Commander right. ans here are some pictures of grees armor parts with the paint colors. Is the camo colors the same? Is the pattern te same? Please help me out here...Im looking all over to get the right collors for paint Thanks in advance Quote Link to comment Share on other sites More sharing options...
trooper1389 Posted October 5, 2011 Author Share Posted October 5, 2011 Should have gone to the CRL in the first place lol to find this... ok going with it lol... Quote Link to comment Share on other sites More sharing options...
mrbungle Posted October 6, 2011 Share Posted October 6, 2011 the base coat is tricky, looks greennish in the shade and tannish in the sunlight..... Quote Link to comment Share on other sites More sharing options...
trooper1389 Posted October 6, 2011 Author Share Posted October 6, 2011 Thanks for the great info on the paints Printed out the picture you have here, and will go and try and get the paints matched and get cracking this weekend on it have some ideas on how to get the paint on it. Will post up pics and how I did it hope this will help out in the future. Quote Link to comment Share on other sites More sharing options...
trooper1389 Posted October 9, 2011 Author Share Posted October 9, 2011 OK to make it more interesting, I went ahead with the flip visor way. Here are some pictures, will post up what I did and how I did it with all the hardware needed to make sure the helmet flip up and down and stays put once on. I lost the pictures that I took where I drew up where I was going to cut, but this will have to do. Make sure you have the visor on and trace an outline on the face where the visor will go so you have an Idea where to be careful in the cuts and where you can chop off and remove parts of the helmet. I ended up removing about 1 inch of material on the face as the visor will be attached to the face and blocking out any gaps. Quote Link to comment Share on other sites More sharing options...
trooper1389 Posted October 19, 2011 Author Share Posted October 19, 2011 Sorry for no updates, did work on the helmet this weekend but have had no time to post up the pictures. I see that the vews here have increases, please leave some feed back with ideas or input regarding this build. I think it will benefit every one here in the long run. Thanks again Marcelo tks1389 1 Quote Link to comment Share on other sites More sharing options...
darren1970 Posted October 19, 2011 Share Posted October 19, 2011 Watching the 'face-flip' mod with interest Marcello, as I'd love to do that on my lid ( a Mr.B ) Quote Link to comment Share on other sites More sharing options...
Guest Ace11144 Posted May 12, 2012 Share Posted May 12, 2012 Can u make me one? Quote Link to comment Share on other sites More sharing options...
Guest cypher1 Posted May 22, 2012 Share Posted May 22, 2012 Anymore pics Quote Link to comment Share on other sites More sharing options...
gatz_ski Posted August 5, 2015 Share Posted August 5, 2015 Marcelo, did you ever finish this face up lid? Been working with mine and finding that the visor arc hits the top dome too much. Attempting to design another swing up hinge or may try something similar to the design I made for the Bly binocs. Gatz Quote Link to comment Share on other sites More sharing options...
CB14440 Posted August 14, 2017 Share Posted August 14, 2017 Hi, could you fix the photo problems? Else it really get's hard to use this post. Quote Link to comment Share on other sites More sharing options...
THUNDERCAT Posted September 10, 2017 Share Posted September 10, 2017 loved this tutorial but pics have gone down :-( Quote Link to comment Share on other sites More sharing options...
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