My first TK helmet build

[AgeOfStrife]

After lurking here on FISD for a few weeks reading up on which helmet kits were worth buying I finally decided on an ATA Works kit. Today I received a big box, and am really happy with the kit. First an obligatory box shot, and the contents. (Links to pics until I can figure out how to have them display, IMG tag doesn't seem to work...)

 

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I've already read lots of build threads, and watched the videos on Trooperbay, and I think I've got everything ready. But before I get started I want to check I haven't missed anything.

 

Looking at the screws I think I've got them sorted out correctly - two large pan head screws with washer and nut that I think are provided instead of rivets to connect the faceplate to the cap, six brass flat head screws with washer and nut that are for the ears, and two resin hovimics with built in thread, washer and nut and separate mesh tips.

 

To cut and sand I've got a heavy duty modeling knife with spare blades similar to an Xacto, various grades of sandpaper, and a Dremel with drill bits, cutting discs and sanding drums. A few threads suggest Fiskar or similar heavy duty scissors, but I have a set of JCB aviation tin snips - left curved, straight, and right curved -that I hope will be suitable, I'll test then on a spare piece of ABS first in case they cause it to crack. Has anyone tried using tin snips?

 

I've also got Humbrol paint Coal Black #55, French Blue #14, Dark Grey #5, and White #22, I'm intending to paint the traps and tears rather than use decals, for the tube stripes I have a Trooperbay standard template set on the way.

 

I'll start trimming the cap and faceplate tomorrow, and probably have a go at a set of ears too. I'll be sure to take pics as I go, and take my time over the build. Any tips along the way will be useful.

 

Dan

Edited January 2, 2022 by gmrhodes13
link not working removed

[Snaps[TK]]

Congrats on getting your brown box. To post pics the will show, click on the picture frame button in the post box options,then paste your link.

[charlesnarles]

Or for mobile I upload to photobucket, click the chain link looking button and copy the "img" link "for forum use" box on the bottom and paste it directly into a post. Have fun

Edited May 12, 2015 by charlesnarles

[AgeOfStrife]

I've got the pics posted on my own server, when I use IMG tags here and submit my edited post either in Tapatalk or using a web browser the IMG tags get removed so they get turned into URL tags. I have no trouble on the phpBB forums I host or on other forums using Tapatalk or a web browser, so can only assume that there's a setting to block IMG tags until a certain number of posts - I have similar settings on my own forums to stop spammers signing up and then posting adverts and links to other sites.

 

As I build I'll add posts and hopefully at some point it will let me embed images.

 

Very impressed with the speed I got this from ATA, I expected it to take a few weeks to arrive but it was in the UK in just a few days after ordering, then got held up in customs till Saturday. I would have had it yesterday but Royal Mail won't deliver parcels immediately that need customs fees paying, but I was able to pick it up this morning.

 

Dan

Edited May 12, 2015 by AgeOfStrife

[AgeOfStrife]

Just got another parcel, thus time the foam, chin straps, and tube stripe templates from Trooperbay. Unfortunately the cuts in the template sheet are misprinted so one stripe is down the centre, and the other is printed over the edge, leaving me with only one usable template. I'll drop him an email tonight.

 

Dan

[charlesnarles]

Aw, that's quite a misprint but don't worry. I'm sure it's rare and that you'll get a free new pair soon. Mine looked spot on but I haven't taken them off yet. Gonna do the white undercoat today actually

[AgeOfStrife]

Started trimming the ABS today, took off the bulk of it with the tin snips and then use the Dremel cutting discs and sanding drums to tidy up the edges. Still need to take a little off on the left side if the cap where it overlaps the face plate as my pencil marks had rubbed off, and the teeth have only been sanded from the back so I can get needle dukes in, but it looks like it'll go together pretty well. I think I've taken enough off the eyes, but the edges could do with a little sandpaper to finish then off. Also started on the ears, I can see these being a pain, good job ATA includes a spare set

 

As to the Trooperbay stripe templates, I'm officially an idiot. Luckily I didn't email yet as I wanted to attach a photo showing the problem, it was at this point I noticed the grey areas that I thought were printed on the background paper are in fact the templates, and the cutout marks are in the wrong place on the paper as the templates had been lifted off the original cut sheet and placed on this smaller piece. So o problems with the templates after all!

 

I do have one question though, I've placed the foam pad inside and tried to put the helmet on, and end up with my eyes level with the frown. Is the foam thicker than usually used, or do i have a big head? Without the foam my eyes are a little above the eye holes. I guess it might fit better with the clamps taken out, will try again once it's all bolted together.

 

I just need to find my other set of clamps before I start drilling holes, I think I know where they are but might need a trip to the local hardware store to get some more.

 

http://www.ageofstrife.com/download/file.php?id=2980&mode=view&d=pic.jpg

 

Dan

Edited May 13, 2015 by AgeOfStrife

[AgeOfStrife]

Not much progress the past couple of days. Trimmed the cap a little more and fitted the first screws to hold the face plate and cap together. Still need to sand the eyes a little more and file the teeth, but at least it looks like a helmet now.

 

http://www.ageofstrife.com/download/file.php?id=2986&mode=view

 

Also trimmed the ears a little more, but still nowhere near close enough to fit. Going to take them slow and steady, hopefully will have them ready to fit by Sunday.

 

Dan

[charlesnarles]

Ears can be difficult, leave way more than you think you'll need when making your first cuts on them. Can't use the lines on the ears as guides, like you can on the eyes. And it's not the end of the world if you have to order more ears. You seem on-track so far

Edited May 16, 2015 by charlesnarles

[AgeOfStrife]

I've made sure I've left extra on the ears so far. Still got a spare pair too.

 

Spent an hour trimming and filling the teeth. I think they're done, but if I need to take a little more off would appreciate the advice.

 

http://www.ageofstrife.com/download/file.php?id=2987&mode=view

 

Dan

Edited May 16, 2015 by AgeOfStrife

[justjoseph63[Staff]]

Looking good, Dan!  And yes, invest in at least 4 to 6 (or more) good clamps, as you will need them when you start on your armor.  If possible, could you get a more close-up pic of the teeth?

[AgeOfStrife]

Not looking to get armour yet. But I do have a good range of clamps including 10 sprung ones and 4 of the trigger ones should I ever go further than just the helmet.

 

Hopefully this pic will be good enough.

 

http://www.ageofstrife.com/download/file.php?id=2988&mode=view

 

Dan

Edited May 16, 2015 by AgeOfStrife

[justjoseph63[Staff]]

Looks really nice, Dan, thanks for the close-up!  It may just be me, but it seems that the opening on the far left is a bit smaller than the one on the far right.  If you want, I would suggest 2 things... You can pick up a set of "Needle Files" from Lowe's or similar.  They come in sets of 6, have different shapes, i.e. round, triangle, half-round, flat, etc., and are PERFECT for the teeth openings.  As a bonus, they only run about 4 or 5 dollars, depending on the brand.    Also, try some 3M silicone sandpaper, (220 grit).   You can bend and shape it, and roll it around the files for sanding, and it will never rip.

[AgeOfStrife]

The ATA cast has the teeth all slightly different sizes. They've been sanded from behind with a Dremel, then filed with needle files (i bought my file sets about 20 years ago), and trimmed with a scalpel, and finally lightly sanded by hand. I might look at opening up the far left tooth a little later on if I get time. Thanks for your comment though, at least I haven't completely ruined them

 

Dan

Edited May 16, 2015 by AgeOfStrife

[AgeOfStrife]

I've messed up the first left ear, took a bit to much off and it's not recoverable. Decided to do the first right ear before attempting the spare left one and ruining that too.

 

I've got the right ear as close as I could without having a meltdown, although I might take a hair thickness off in a few places (marked in pencil) when I take it off again to countersink the screw heads and wash the helmet before painting.

 

http://www.ageofstrife.com/download/file.php?id=2989&mode=view http://www.ageofstrife.com/download/file.php?id=2990&mode=view http://www.ageofstrife.com/download/file.php?id=2991&mode=view

 

Do these gaps look acceptable? I've compared with some images from ANH and the gaps range from hairline to buy enough to drive a truck through.

 

Dan

[AgeOfStrife]

Did the left ear, happy with the result although it's a little thicker than the right. I might try to replace the right ear with the spare if I can trim it to the same thickness as the left. I might also notch the tips of both ears to help close up the gaps near the tops.

 

http://www.ageofstrife.com/download/file.php?id=2992&mode=view http://www.ageofstrife.com/download/file.php?id=2994&mode=view http://www.ageofstrife.com/download/file.php?id=2993&mode=view

 

I now know why everyone says the ears are hard to get right!

 

Dan

[charlesnarles]

That ear is really thin, especially on the leg/stem/non-circular part. If that covers your right seam then I'm impressed lol. I don't think it's "too thin" but you could leave a little more meat on next time. Kinda looks like a hero ear rather than stunt. Good idea to keep reference pics handy for comparisons at every step. Seriously good job on making that particular fitting lol you should look at the Anovos right ear, especially from behind.

Edited May 17, 2015 by charlesnarles

[AgeOfStrife]

Both ears cover the seams, the right was a bit close though. I think I will trim the spare one to match the left better, probably later in the week. I had pics as I was trimming, but got a little carried away on the right, and as the ear beds to match the shape of the tube there's not much leeway. While it didn't take as long to do the second attempt at the left ear, i did take less material off each time so didn't need to keep going over the same areas repeatedly which I had to do on the right.

 

Dan

[AgeOfStrife]

The thinner right ear bugged me, so tonight I've trimmed the spare right ear and much happier with it, pretty much the same thickness as the left one and looks more balanced now.

 

Here's a photo showing the two right ears, the first one is at the back and clearly much thinner. http://www.ageofstrife.com/download/file.php?id=2996&mode=view. And here it is from the front fitted on the helmet. http://www.ageofstrife.com/download/file.php?id=2995&mode=view

 

I've now dismantled the helmet, hand sanded all the edges to remove any burrs, countersunk the screw holes on the ears, and washed all the parts to get rid of dust, pencil marks, and mould release. Will leave it overnight to dry out thoroughly, should be able to start painting tomorrow evening.

 

Once the painting is complete and the helmet put together I'll fit the visor and chin strap, and then trim the screws back - almost took an eye out trying it on earlier :/

 

Dan

[firebladejedi[TK]]

You definitely over trimmed the first ear, probably by following the mod lines as a guide? Easy mistake. Second set do look better.

 

If you are going to paint it I would paint it while its all assembled no point to painting it in pieces to then build it up again, just build, paint,

detail.

[Sonnenschein]

If you look at the Brian R helmet, the left ear is quite thin

 

[AgeOfStrife]

On that helmet both ears look similar, at least to me. On mine the right ear was about half the thickness of the left.

 

I was going to paint before building it again as trying to paint on a helmet rolling around will guarantee I'll mess it up. At least with the parts separate I should be able to get the areas to paint in comfortable positions, and I had to take it apart to wash the parts so it's already in pieces on my table.

 

Dan

Edited May 19, 2015 by AgeOfStrife

[AgeOfStrife]

Started painting, so far got the traps and tears filled with black (the grey doesn't like going straight on the ABS, the solid black should give it a base to adhere to), outlined the ears (should have filled them with black, will see how the grey goes), vocoder and hovimics painted black, and placed the tube stripe templates.

 

http://www.ageofstrife.com/download/file.php?id=2998&mode=view http://www.ageofstrife.com/download/file.php?id=2999&mode=view

 

Do the templates look to be in about the right place? I have them about a pencil width from the vertical part of the faceplate, and added 10mm masking tape to stop them lifting. Going to paint the stripes white first, then French Blue when the white is dried.

 

Time to start the grey

 

Dan

[Sonnenschein]

Going to paint the stripes white first, then French Blue when the white is dried.

 

That's how it's done correctly. This avoids the darn "bleeding" of the paint.

 

The template looks fine to me

[AgeOfStrife]

I painted the tube stripes white, left them overnight to dry, then did the blue. Left that for a couple of hours (I'd read that the template should be removed before the paint dries fully to prevent peeling it off), and then peeled off the templates to find this.

 

http://www.ageofstrife.com/download/file.php?id=3000&mode=view http://www.ageofstrife.com/download/file.php?id=3001&mode=view

 

Left that to dry fully overnight, then carefully picked at the bleeds with a cocktail stick this morning.

 

http://www.ageofstrife.com/download/file.php?id=3002&mode=view http://www.ageofstrife.com/download/file.php?id=3003&mode=view

 

All the painting is now complete, including freehand on the stripes on the tears and traps. Just got the visor and chin strap left to fit before trimming the screws inside. Should be able to post finished photos tomorrow.

 

Dan