OPERATION OMG REBUILD!!!!

[TK-4510[501st]]

More...

[TK-4510[501st]]

Now its time to mount this bad boy to the cap n back. Draw a straight line from the edge of the eyes up on both sides like this...

[TK-4510[501st]]

I grab a couple of clips and line everything up the way I want nice and even.

[TK-4510[501st]]

Once everything is lined up I can drill new holes and rivet the cap to the face. Looking good!

[TK-4510[501st]]

Now since the ears were already trimmed we can skip that step. Ah, feels nice... But I notice that the ear does not fit exactly as I want to. It needs to be slanted a bit further back. I mark the cap with a pencil where extra material needs to be taken off.

[TK-4510[501st]]

*

[TK-4510[501st]]

Once I have the ear right where I want it I drill the top hole and put in a screw just snug. Then I line up the bottom just where I want it and drill the bottom hole while holding the parts together tightly. Notice that I am using a heavy leather glove so I dont drill through my thumb (again). Once the bottom hole is drilled I put in another screw and tighten it snug. Then repeat for middle screw. Looks good!

[TK-4510[501st]]

To make sure everything is even looking I am going to measure from the tear to the ear. I then mark that same distance on the other side.

[TK-4510[501st]]

Then I am just going to mount the left ear to the other side...

[TK-4510[501st]]

And now I present to you......... THE OMG TE2

[TK-4510[501st]]

Before...

 

After:

[TK-4510[501st]]

I am going to trim the bottom to make everything nice, when we come back!!!!!!

[Ironclaw]

Totally AWESOME work Mike!. Super nice cutting and the new front looks much better. I like how the eye bump is gone

[Murray1134[501st]]

Not only is this an amazing rebuild, but it's also a terrific resource for anyone building a helmet from now on.

 

Amazing, simply amazing.

[Boozel]

wow mike...awesome

[Daetrin[Admin]]

I'm floored! You make it look so easy, but it's an incredible skill you've developed.

[nice-biscuit]

I like the 'before' and 'after'. There are certain thing a novice like me could inadvertently do. This is getting as good as your other thread.

[TK-4510[501st]]

Primer, sand, primer, sand, primer, sand...... When will it end....Soon! Today Thats what I did. I also put another coat of glazing putty on the helmet and cracks.

[TK-4510[501st]]

I decided to fill in the chips around the teeth with some bondo too....

[TK-4510[501st]]

I sand down the bondo with some 80 grit once it dries......Then wet sand the whole thing....again!

[TK-4510[501st]]

After it dried I primered it again. Next comes light sanding, tack cloth and paint!!!

[Darth_Nickel]

Well done!!! It's looking great man.

 

BTW... what was the second bucket, with the seam you were working on? Was that a new ANH?

[TK-4510[501st]]

LOL!!! yeah I am doing a KW ANH for Sam, our Squad Leader here in San Diego.

[Darth_Nickel]

very nice!!!! is it a v2 or v2.5? Looks like a V2?

[TK-4510[501st]]

I think its a 2. I know the molds are destroyed for this version. he is making another soon.