ATA helmet build...stumbling block

[silverBoyd[501st]]

I've built a few helmets: MTK TK helmet, Tusken, Royal Guard, etc...

 

I'm to the point where I am almost ready to fit the 2 halves together. I have trimmed and although I know some trimming (around head opening) is still needed, I can't seem to see how it will fit together properly during a test fit.

 

I'm stressing over this helmet...something isn't right with this rear cap. It's not shape right. I know the ear caps cover it up but it's the bottom near the opening (on both sides) & the way it looks like there will be a gap left out that won't have anything for the black finishing trim to grab onto....

 

It's just a weird shape to the cap back. The sides are making me bonkers. The way they are it seems even after I put on ear caps it still won't look right.

 

The rear cap is lined up and centered on the faceplate via clamps so why are the sides giving me such a fit? Could it be a bad vac-form pull?

 

Any help or thoughts would be appreciated.

 

 

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Edited September 25, 2015 by silverBoyd

[pattrooper]

Did you trim the back cap first?

[silverBoyd[501st]]

Yup. Trimmed bottom, brow & sides. It's just not looking right. I'm nervous to fasten it together

 

 

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Edited September 25, 2015 by silverBoyd

[pattrooper]

Before I trimmed my bucket I aligned it all and kept it in place with painters tape. then drew the lines for trimming...and did a little at a time. Never trim before you know where to trim. You might be able to save it.

[silverBoyd[501st]]

I've really not taken much away at all as far as trimming. The helmet is held together with clamps and even before I trimmed the rear cap wasn't lining up with faceplate as far as the sides and bottom are concerned.

 

 

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[pandatrooper[TK]]

One side sticks further back than the other. I can't recall which but one side "just" has room for one rivet leaving a gap from front to back. Check my build thread.<br><br>

<a data-ipb='nomediaparse' href='http://www.whitearmor.net/forum/topic/14806-how-to-assembling-ata-abs-helmet-1/'>http://www.whitearmor.net/forum/topic/14806-how-to-assembling-ata-abs-helmet-1/</a><br><br>

Just line up the eyes evenly and clamp it in the ear area, and drill the upper bolt hole for the ears on each side.

[wingnut65[Staff]]

I'm hitting my ATA helmet this weekend, so I am listening...  Thanks Terry for reminding me of your thorough build thread.   I know what I am doing on my lunch hour...
 

Jason, in your pix, it looks like there still might be the extra flashing on thelmet back around the tube areas that are preventing the back from mating with the front. Here is where you have yours now:

 

And here is where pandatrooper has the lines that need to be cut along the side and around the tube area.

 

I see you did trim some back on yours, but there still is rough edges and no curved opening for the tubes.

 

Just a thought...

[illusionz_09[TK]]

the misalignment gets covered by the ears anyway and then the rubber s-trim.

Just cut accordingly and then put the screws in place. 

it may take a little manipulation, but it all comes together in the end.

[silverBoyd[501st]]

thanks for the tips everyone.

 

I've been fretting over this piece.  This ATA is so different from other TKs I've assembled. As far as the sides are acting.  I spent 2 hours fine tuning and making small trims and here is where I am at.  I don't think I can trim anymore.  If I do, I won't have anything to grab onto when screwing the (2) halves together.

 

The "tubes" are lining up much better now on the sides

[charlesnarles]

Keep looking at different ATA builds and original helmets for reference. The tubes might not be how you want, but more about what the helmet wants for this step. Trim the head opening after assembly to get as even a line as possible at the connection

[hon143]

I know that many here will be up in arms about this.....but, when I was building my bucket, I used a heat gun to carefully, gently, and slowly mold the bucket pieces to line up correctly. 

 

I had a microfiber cloth in hand.  Then, I would heat up an area for only about 5 seconds in a circular motion.  I would NOT heat up an area with the heat gun in one location and stationary.  When the area was semi-softened, I would use the cloth to smooth over that section to align the side tube bumps better. 

 

Note, the ears will cover much of the misaligned portions. 

[pandatrooper[TK]]

You need to cut off the areas I indicated here in red, and drill the holes where the blue dots are.

 

There might be a gap, but it doesn't matter. The ears cover it.

 

[silverBoyd[501st]]

THANKS PANDATROOPER

 

I'll try taking out a bit more on those "S" curves. It's getting there though.  Better than where it was yesterday.

 

I'm feeling better about it

Edited September 26, 2015 by silverBoyd

[silverBoyd[501st]]

 

Panda....I took out more "real estate" in those areas and it definitely helped to pull things down to line up better.  I think I can still take just a few mm on the right side and then I think i'll be good to finally assemble and drill a few holes

Edited September 26, 2015 by silverBoyd

[silverBoyd[501st]]

 

 

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[charlesnarles]

My ATA looks like yours; the cap wants to rotate slightly to the right (note where the traps line up to the eyes) so I think you're okay. Go slow on the ears! lol

Edited September 27, 2015 by charlesnarles

[pandatrooper[TK]]

Looks much better. Expect my invoice in the mail.

[Ryth_[501st]]

Got the same gap on mine ginos right side as well. Ears will cover that nicely.

[silverBoyd[501st]]

Working on ears. Going slow but I think they are still a touch too thick.

 

 

 

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[pandatrooper[TK]]

Flatten them out more, they should be a more even thickness. Right now they are thicker at the top of the disk than the bottom

[illusionz_09[TK]]

Yes, what panda is saying. Make sure you trim/sand the ears thinner so they can align and fit properly around the disk.

[Elumusic[TK]]

I'm hitting my ATA helmet this weekend, so I am listening...  Thanks Terry for reminding me of your thorough build thread.   I know what I am doing on my lunch hour...

 

Jason, in your pix, it looks like there still might be the extra flashing on thelmet back around the tube areas that are preventing the back from mating with the front. Here is where you have yours now:

 

And here is where pandatrooper has the lines that need to be cut along the side and around the tube area.

 

I see you did trim some back on yours, but there still is rough edges and no curved opening for the tubes.

 

Just a thought...

 

 

Exactly!!!!!

[silverBoyd[501st]]

got my ear caps looking better and thinner on both sides now.

[illusionz_09[TK]]

much better!

[jr1203]

Looking good, Jason!

 

Any completion pics?