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Endor soft helmet re-visit
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Schph Gochi (Phyllis Schulte)
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PostPosted: Tue Feb 19, 2013 8:29 pm    Post subject: Endor soft helmet re-visit Reply with quote

Nar Shaddaa Base is participating in a rather large event coming up in June and because the Empire and the Rebellion are doing a combined helmet/headgear exhibit
and
we will also be having a second display at what is to be the Rebel Base (Imperials will be at the Joliet Library and the Rebel Base will be a block away at the Joliet Historical Museum)..
I found myself in need of two sets of head gear for HRS and ERS.

I have had extra pieces of things laying around for years and it became time to finish building these extra pieces...





I didn't have a lot to do on the second HRS hat/headgear. I had found some vintage ski goggles on E-Bay a couple weeks ago so I just needed to take out the blue elastic strap and trade it out for plain white elastic. I also had to make the small tan piece that the hat comm fits on and finish my second hat comm.....done..


The Endor Commando will be a whole start from scratch thing. I do have an extra donut that I started to cut and sand...
but..
I am not going any farther on that till I finish the ANH 15.
I have done an ANH from scratch...and since I didn't like the plastic ear caps...I made this one for a friend using black felt and incorporating the hat bill into the ANH..



I did like the above version....
but for the ANH for my second set of headgear I won a real ANH 15 at auction for cheap because it is in bad shape...and is a medium...which is rather small......but I can save it by re-sectioning the parts that will be hidden under the center ribbed/pleated piece...
so..
it was time to take another look at making a second pleated piece...

Here is a screen shot showing that in all likelyhood the center piece of the soft cap in ribbed rather than pleated...



Experimenting around with cording and fabric...
start of ribbing setting on top of my current pleated piece...




Not sure which way to go ...
ribbed
or
pleated
Neither one will be a barrel of laughs to produce...
Wink
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Jedi_Boyer (Michel Boyer)
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PostPosted: Fri Feb 22, 2013 2:24 am    Post subject: Reply with quote

Best of luck with this. I have been meaning to tackle this same project for about a year now. I have on headgear I picked up in a trade a few years ago, but I just don't like the way it fits. Please keep us updated on your progress.
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Landeaux (Paul Land)
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PostPosted: Mon Feb 25, 2013 4:18 pm    Post subject: Reply with quote

When I did my ERS soft helmet, I placed batting between the fabric then sewed ribs in. Depending on the thickness of batting and space between ribs will change the way the ribs look.
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Schph Gochi (Phyllis Schulte)
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PostPosted: Mon Feb 25, 2013 4:51 pm    Post subject: Reply with quote

I had considered that quilting approach...
but felt that the cording would give it a more pronounced rib than just quilting...
still awating the ANH in the mail...
then I can move forward on the ribbing...if it doen't end up looking good..
I will probably use the pleating again.....

Wink
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PostPosted: Sun Mar 10, 2013 7:21 pm    Post subject: Reply with quote

Hey Phyllis, have you tried using cording to do the center piece. I just received like new ANH15 helmet that I won on ebay. I'm going to redo mine with the quilting method unless the cording works better
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Schph Gochi (Phyllis Schulte)
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PostPosted: Sun Mar 10, 2013 10:39 pm    Post subject: Reply with quote

Landeaux wrote:
Hey Phyllis, have you tried using cording to do the center piece. I just received like new ANH15 helmet that I won on ebay. I'm going to redo mine with the quilting method unless the cording works better


Funny you should ask...
my ANH came yesterday...so that means I will be working on it at some point this week...

I tried two ribs with the cording...just to see what it looked like
I used a zipper foot on the sewing machine to try to keep the stitching right up against the cording...it takes some effort...but not too bad
...
but...I am wondering if the cording that I have might be a bit too large.
I might have to dig around the house and see if I have something else...

will post some photos later in the week...hopefully

Very Happy
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Schph Gochi (Phyllis Schulte)
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PostPosted: Sun Mar 17, 2013 1:33 pm    Post subject: Reply with quote

Back to this project
and it is going pretty bad...lol...

First off, since this is for an exhibit ...I felt I needed to be as close to the movie version as possible...so I needed a real ANH
But...not wanting to cut apart a pristine example of WWII memoribilia, I sought out one that was not in really good shape. I found one (size medium) that had some wear and tear issues and was probably not stored under the best of conditions.

Because it is a medium...I wanted to make it larger...

So I cut the halves apart....
and made a spacer of sorts to make it larger...
note the difference in hard helmets ...the one on the left is my regular ERS I troop with and the white one on the right is the one that will be fitted to the new soft helmet for the exhibit...






Here is the spacer strip being sewed in:







And the end result.....the spacer and the hat bill (which I since removed again because I felt that the hat bill was too large)




I then notched the bottom of the donut to accompany the soft helmet and tried it out for size



and

from the top....




As noted...
the bill is off of it again as I do have to re-make it and the ribbed piece will cover up the spacer nicely when that is done. As soon as I am happy with the soft helmet, cap bill and fit to the hard helmet...THEN I will start the ribbing process...
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Schph Gochi (Phyllis Schulte)
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PostPosted: Sun Mar 17, 2013 4:46 pm    Post subject: Reply with quote

ok..
things are looking up...
re-did the bill and put it back on and started the ribbing...
and..

I think this will work out pretty good...but before I go any farther ...
wanted to see if there was any thumbs up...or down....

What I did was cut apart an old macrame' hanger...
yes...
you read that correctly...
because the cording I purchased was actually too large...so rather than run out and look for something else..
I just looked around the house...
and voila'
a macrame' plant hanger with about the diameter cording I was looking for...

so...I started the ribbing process using the cording..starting up a bit as you don't see that first 1 or 2 under the hard helmet...and I didn't want to add bulk...
so..
I sewed a starting line and using a zipper foot and my sewing machine set with the needle to the left...
I sewed in the first piece of cording...
then the second butted up against the first..
and so on...





It isn't positioned correctly in this photo under the hard helmet...but I just wanted to see what the ribs looked like...




All in all...
I think it will look pretty accurate...

You start with a "sized piece" on the bottom...
and put a much longer piece on top as you (of course) will need the extra fabric as you cover the ribs...




Thoughts?
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PostPosted: Mon Mar 18, 2013 1:40 am    Post subject: Reply with quote

I think you hit on the way it was done, looks pretty accurate. A closer inspection of the screen shot in your first post looks like cording or similar was used and to me it looks like alternating sizes of cords. Like between the size you used is one half that size. I'm definitely going to try this technique and use it on my new helmet.
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Schph Gochi (Phyllis Schulte)
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PostPosted: Mon Mar 18, 2013 7:44 am    Post subject: Reply with quote

Sometimes when I look at the photo it looks like two sizes of cording..
and sometimes it just looks like one size...
perhaps it is the "weathering" that makes it appear as two sizes...
dunno...
but I am going with only the one size..
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Schph Gochi (Phyllis Schulte)
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PostPosted: Sat Mar 23, 2013 5:49 pm    Post subject: Reply with quote

oki-dokey....
well...
I finished things up and tried to take a photo of the headgear on....
lol...
as an excercise...try taking a photo of the top of your own head...

I also took a few photos of the piece on my make-shift head....which actually isn't very good cuz it is too small and not really "head shaped"....

anyway...

what we have so far...








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PostPosted: Wed Mar 27, 2013 12:04 am    Post subject: Reply with quote

that looks really good!
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Schph Gochi (Phyllis Schulte)
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PostPosted: Fri Mar 29, 2013 9:50 pm    Post subject: Reply with quote

Ready for the exhibit..


the styrofoam head is still smaller than an average head...
I think that the male ones I bought were still under 22 inches...and I don't think my head is that large cuz that Naboo Pilot bucket fits on my head...and I think my Imperial Officer hat is like a 23 1/2" size...
so..
these heads are still small and you can tell by the way the soft helmet sits on it...





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PostPosted: Tue Apr 02, 2013 3:33 am    Post subject: Reply with quote

Awesome work as usual!
I always felt the top was ribbed as opposed to pleated. I tried and tried different things without much luck, but you seamed to have nailed it. Good job!
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TrooperPX (David Ramsay)
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PostPosted: Mon Jun 17, 2013 2:10 pm    Post subject: Reply with quote

I really like the ribbing. It has a similar feel to the X-Wing vest, and that really came out great. Padding or "armor" on top makes sense and I may tackle this when it comes time to upgrade ours.

Thanks for the R&D!
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