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Rebel pilot helmet build... with a twist

 
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Walter ()



Joined: 03 Sep 2015
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PostPosted: Wed Jul 05, 2017 5:06 am    Post subject: Rebel pilot helmet build... with a twist Reply with quote

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
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PostPosted: Wed Jul 05, 2017 5:08 am    Post subject: Reply with quote

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)



Joined: 20 Aug 2008
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PostPosted: Wed Jul 05, 2017 12:27 pm    Post subject: Reply with quote

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
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PostPosted: Wed Jul 05, 2017 12:42 pm    Post subject: Reply with quote

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 ()



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PostPosted: Wed Jul 05, 2017 2:59 pm    Post subject: Reply with quote

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 ()



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PostPosted: Wed Jul 05, 2017 11:18 pm    Post subject: Reply with quote

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 ()



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PostPosted: Thu Jul 06, 2017 5:03 am    Post subject: Reply with quote

So Droidboy started with Wedge!

greggs wedge progress 2 by Bryan Babich, on Flickr

greggs wedge progress 3 by Bryan Babich, on Flickr

greggs wedge progress 4 by Bryan Babich, on Flickr
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Blue Banshee Leader (Alex Buirch)
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Joined: 05 Jul 2008
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PostPosted: Thu Jul 06, 2017 6:26 am    Post subject: Reply with quote

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
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PostPosted: Fri Jul 07, 2017 5:05 pm    Post subject: Reply with quote

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 ()



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PostPosted: Wed Jul 12, 2017 2:08 pm    Post subject: Reply with quote

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
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PostPosted: Fri Jul 14, 2017 4:02 am    Post subject: Reply with quote

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
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PostPosted: Fri Jul 14, 2017 6:22 pm    Post subject: Reply with quote

Very cool
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Toda ()
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Joined: 08 Mar 2012
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PostPosted: Fri Jul 14, 2017 6:50 pm    Post subject: Reply with quote

I agree with SeanTX, very cool!
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Todd (Toda) - RAID XO
A-Wing Pilot, Endor Gunner, RFT, and Rebel Technician, TFA officer




"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)
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Joined: 02 Jul 2017
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PostPosted: Tue Sep 12, 2017 4:01 pm    Post subject: Reply with quote

I'm starting work on my helmet. Would you mind sharing how you mounted the visor? Thanks!
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Walter ()



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PostPosted: Mon Dec 11, 2017 3:55 am    Post subject: Reply with quote

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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