ESB TK Helmet Build [*ATA]

[Darth Ruprecht]

Big thanks to Terrell for his amazing work in his craft. I am thoroughly satisfied with not only the purchase process but also the product.

 

 

Now, here's a couple questions before I dig in too far.

 

I've read a few posts where folks have sprayed the interior of their helmets with things from truck bed liner to plasticote, I would imagine this would be easier if you did it at the start instead of after assembly, however any one have suggestions on product/whether this is a good idea?

 

I've read several of the threads on this, namely Pandatroopers break down of it, and feel pretty good going into this, but honestly I'm still a bit terrified to screw this up.

 

Any last minute suggestions before I start marking and cutting?

 

Wish me luck!

Edited May 10, 2011 by Darth Ruprecht

[v7sg[TK]]

The only suggestion I have is that you take your time with the helmet and don't rush into it. Measure twice, cut once as it is often said around here.

[BananoPower22[TK]]

As Christian said, take your time and be extra careful when trimming. Always be sure to cut less so you don't over trim and you end up wrong (this goes specially for the ears trim a little, see if it fits, if not, cut a little more, etc. until you get a perfect fit )

 

And be sure to post pics of your progress!

[naatsirhc[TK]]

Mathew,

I used the spray on Plastidip for the interior of my bucket. This leaves a nice finish. TK-4510's helmet tutorial will prove a great resource when it comes to building your ATA. Have fun with your build

[Darth Ruprecht]

Where can I find TK-4510's tutorial?

[Sonnenschein]

It is pinned in the helmet section and downloadable in the "how to section". But I'd suggest to get the printed version from Mike's site. Quite handy!

[Darth Ruprecht]

Awesome. Will do.

 

I can't wait to get started on this tonight. It's a great distraction after studying for a pair of Microsoft tests this Friday.

 

Busy week!

[Darth Ruprecht]

First night of work. Some may call me over cautious, however I like to say I am simply prepared.

 

Not only did I tape the outside of the helmet to prevent overspray from the interior paint, but I also left the plastic sheeting on. Two layers of protection is better than one, right?

 

 

I also covered the ATA logo on the inside of the helmet. It may seem silly but I wanted to maintain the source of the helmet.

 

 

Interior covered with the first coat.

 

 

 

Now to let it dry and prepare to begin cutting.

Edited May 11, 2011 by Darth Ruprecht

[1mpulseS0D]

Looks nice, what did you use to cover the front and back of the helmet? Also how glossy/mat will the interior be after drying?

[Darth Ruprecht]

I used Scotch brand blue painters tape. The paint ends up being a matte black with a slight texture.

 

I will be out of town tonight, but will try to get a better picture of the end result once I return home tomorrow. Hopefully you'll be able to see what I'm talking about then.

[Darth Ruprecht]

So I passed both of my Microsoft tests today. New addition to the alphabet soup behind my name.

 

Here are the detail pictures I promised of the interior of the helmet. I haven't started cutting, yet. Still measuring, double measuring, checking my sources, re-measuring. . . Thinking about how I measured, etc.

 

Detail of the interior of the helmet. The coating added a lot of extra rigidity and a nice finished look.

 

 

Maintained the Maker's Mark.

[Darth Ruprecht]

Cut line for the lobotomy.

 

 

 

Anyone have thoughts on the cut line? Does it look straight?

Edited May 14, 2011 by Darth Ruprecht

[Darth Ruprecht]

Eyes cut out.

 

 

 

 

 

 

Thoughts?

[Brett]

Very nice cuts, looks really "clean"!

[Darth Ruprecht]

I was surprised how well it cut. This was my first foray into the world of dremel cutting. Apparently patience pays off.

 

Still not sure about the line for the forehead, though.

 

Thoughts?

[BananoPower22[TK]]

Looks good. Does the black coat you gave to the inside of the helmet changes the look on the outside?

[Darth Ruprecht]

Not at all, no. At least none that I've seen so far. I'm still cutting and assembling, though.

[Sonnenschein]

Good start!

 

Is that you in the avatar? A strinking resemblance to Adam Savage!

 

[Darth Ruprecht]

Yes, that's me.

 

I've been told that before. I showed my wife that post and she agreed. Now, if only I had his money and awesome job. . . .Hmm. . .

 

Anywho, need to Stay on target!

 

I've cut the teeth out and trimmed down the top of the faceplate.

 

 

 

 

 

I also trimmed down the cap and back, but was wondering if I should trim down the back of the lid further?

 

 

 

 

 

What do you all think?

[Sonnenschein]

nice job on the eyes, but file the nose holes a little more "squarer"

 

oh, and cut the fourth hole, unless you go hero

Edited May 14, 2011 by Sonnenschein

[Darth Ruprecht]

Is there a hero designation for ESB? If so, what are the combinations so I can be sure.

[tkrestonva[TK]]

The only "Hero" is in ANH, and it specifically refers to Han and Luke when they were disguised as stormtroopers on the Death Star.

 

So no, there is no ESB Hero.

[Darth Ruprecht]

Okay, thanks for clarifying, Brian.

 

I did end up opening up the teeth a bit more with the dremel, however.

 

I am now trying to determine how to line the helmet and faceplate up to join them with rivets. Perhaps I'm just clumsy but I don't see how to do this.

 

Suggestions?

[Darth Ruprecht]

Well, I've joined the faceplate to the lid.

 

Here's the result.

 

 

 

I had a bit of a "Oh $*@&%" moment when I realized one side was higher than the other on the brow. I was able to correct this by using the dremel to clear material from the lid above the problem eye. All in all I believe it could have been better, but as this is my first I am fairly satisfied so far.

 

 

 

You can see here where the brow trim dips at the trap on this side.

 

 

I also found an interesting issue when I actually test fit it. . . . My enormous eyeglass frames actually protrude slightly from the lens areas. Hmm.

 

[TK-2126_MD[TK]]

Looking very nice!!!! have to saw that one of the cleanest work area i have seen in a good while!!!!!! maybe to clean......

really looks like u have been doing this a awhile and not your first helmet. really looking foward to see u build your armor.

Once again welcome and glad u found us