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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Wed Jul 05, 2017 5:06 am Post subject: Rebel pilot helmet build... with a twist
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I know, this one has been done many times, but Droidboy and I put our heads together and decided to do something a little different. We have wanted to build a really good X-Wing helmet forever, but we wanted it to be durable. We went to work on a design that would give us the classic look, be 10x or more durable than vacuformed styrene. I will be posting Droidboy's build and some of my own (I am not as far along as I am working on templates for my own helmet decor).
First, some reference.
Luke pilot helmet by Bryan Babich, on Flickr
The first one is totally straight forward.
And then we get to Rogue One...
RO Reference 1 by Bryan Babich, on Flickr
RO closeup by Bryan Babich, on Flickr
Ok, you can't see it in the first image and but the mohawk cap, the front is different. There are other variations as well (also well documented it, I am just laying this out from a project perspective), but this difference inspired us to create a helmet that would work for RO and OT. Seriously we just wanted a sturdy helmet that when we dropped it on the ground wouldn't destroy our hopes and dreams and we wanted it to look and feel just right. |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Wed Jul 05, 2017 5:08 am Post subject:
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We found this picture from Rogue One and it was very telling about the methodology in making their helmets.
RO Reference 2 by Bryan Babich, on Flickr
We also determined the best route for the mohawk caps was to laser cut a master.
Laser cut RO OT toppers by Bryan Babich, on Flickr |
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ywingfighter (Frank) Active Legion Member
Joined: 20 Aug 2008 Posts: 384
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Posted: Wed Jul 05, 2017 12:27 pm Post subject:
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Hi Walter,
the OT and Rogue One helmets are very differend. The helmet halfs of this versions are made from ABS and the Rogue One helmet had an inner helmet shell and movable visor. The Visor of the OT helmet is in static position. |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Wed Jul 05, 2017 12:42 pm Post subject:
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Thanks. I do see the differences... just taking you on our projects journey. You will see what I mean shortly.
Last edited by Walter () on Wed Jul 05, 2017 6:23 pm; edited 1 time in total |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Wed Jul 05, 2017 2:59 pm Post subject:
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The other challenge we had with the styrene helmets was the assembly, it is not fun. So far, I have been talking about the challenges with the helmets because I want you to see where we were coming from when we started to pull this all together. We worked with our team of fiberglass experts to challenge them if they could make a decent fiberglass helmet, not too thick, but retain the resiliency of the material.
Helmet interrior by Bryan Babich, on Flickr
Helmet interrior 2 by Bryan Babich, on Flickr |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Wed Jul 05, 2017 11:18 pm Post subject:
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Here is Droidboy's helmet, all primed and ready to go.
proto helmet by Bryan Babich, on Flickr
We also printed out the buck for the visor which you can see in the photo and a trimmed chin cup. |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Blue Banshee Leader (Alex Buirch) Active Legion Member

Joined: 05 Jul 2008 Posts: 4560 Location: Portland, OR, USA Medals: None
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Posted: Thu Jul 06, 2017 6:26 am Post subject:
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That's looking interesting. Nice job!
One thing I spotted, though, is that the "latches" on the front sides of the helmet should have three circular indentations on the top and bottom. |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Fri Jul 07, 2017 5:05 pm Post subject:
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They are on there, just not as pronounced as I would like. For mine I may make them much more pronounced by putting in rivets or something along those lines. It's fiberglass so I can totally do that and have little to nothing to worry about. |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Wed Jul 12, 2017 2:08 pm Post subject:
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Aaaaaannnnndddd... finished (mostly). A lot of people over the years have taken red fabric dye to tint the lens, we did something a little different. Droidboy applied Krylon stained glass spray paint that you can pick up at hobby lobby, ACE or online and sprayed the back of the lens. It looks splotchy at first but evens out as it dries and looks great.
greggs wedge progress 6 by Bryan Babich, on Flickr |
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Fri Jul 14, 2017 4:02 am Post subject:
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Sooo.... we made a few extras... I think I will need to start a for sale thread.... |
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SeanTX ()
Joined: 27 Feb 2015 Posts: 157 Location: Grand Prairie Texas Medals: None
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Posted: Fri Jul 14, 2017 6:22 pm Post subject:
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Very cool |
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Toda () Detachment XO


Joined: 08 Mar 2012 Posts: 705 Location: Clarksville, IN Medals: None
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Posted: Fri Jul 14, 2017 6:50 pm Post subject:
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I agree with SeanTX, very cool! _________________ Todd (Toda) - former RAID XO (2017-2019)
Endor Gunner, RFT, Rebel Technician, TFA officer, TFA Trooper, and A-Wing Pilot
"Any pilot who volunteers to fly an A-wing better be brave or crazy. Probably helps to be a little of both."
―General Han Solo |
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Wingspan (Mark Wolf) Active Legion Member

Joined: 02 Jul 2017 Posts: 21
Medals: 1 (View more...)
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Posted: Tue Sep 12, 2017 4:01 pm Post subject:
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I'm starting work on my helmet. Would you mind sharing how you mounted the visor? Thanks! _________________ R2-D2 Builder. Rebel Legion, 501st Legion
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Walter ()
Joined: 03 Sep 2015 Posts: 25
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Posted: Mon Dec 11, 2017 3:55 am Post subject:
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For sure. I did it with the velcro that I included in the kit... I am also looking at other alternatives as well. |
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