ROTJ reinforcement for Austria & the Empire

[Maxl[TK]]

Me too

Works perfect but stinks like hell for ages!

 

Does it works better than hot glue, or is that the same?

Edited September 10, 2016 by Maxl

[humperdingle]

Does it works better than hot glue, or is that the same?

I've always found that hot glue eventually separates from a flat surface, especially a surface that flexes. For example, the anchor points in the helmet for the harness were hot-glued, but didn't last long. It's now stuck there with velcro.

[scott.lindsay.5209]

I'm not having great success with sealant. Seen a post with milliput and screws.

 

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[Maxl[TK]]

hm, ... maybe I have to search for another glue or silicon or whatever ( )

[Maxl[TK]]

After a long break it's time for going on assembling.

 

The helmet is already glued, but first time the sides of the helmet have been released again.

 

 

So I had to glue it again. Now it looks better

 

 

 

 

 

 

 

Now it is time to cut the ears off .... pfuh .... this is realy hard work :blink:

 

many times cutting and test fitting again and again ...

 

 

I set a mark to know where to place the ear pieces:

 

 

more pictures will follow ... till then ... cu!  

[scott.lindsay.5209]

Lovely

 

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[Maxl[TK]]

Lovely

 

Sent from my HTC One_M8 using Tapatalk

 

Thank you!

 

The left "ear" is ready now and fits very well.

 

 

 

 

 

 

 

I hope that the right "ear" fits well too, cause I think that I cut too much off of it. Perhaps I can set it right.

 

Does anyone have an idea how to glue the "ears"? Because when I clamp the "ears" the clamps would slip away

[Maxl[TK]]

After a long, long work I finally finished the "right ear". I hope that I can glue it somehow

But all anticipated here the operation:

First roughly mark and cut:


Then always cut cautious. It is really important to do not cut off too much!!! Do it again and again till it fits! (very easy ... )











That was a really really hard work for me. Not even the strapping has taken me so long. Now I have to glue it ... somehow ...   I don't know HOW to clamp!!!!! Can anybody help me, please?

[troopermaster]

Because when I clamp the "ears" the clamps would slip away

What kind of clamps are you using?

 

I use these:

 

One through the eye socket and one on the bottom of the helmet. They can be tricky to fit so I do one side at a time to make it a bit easier.

[Maxl[TK]]

I use these clamps. But they are too strong for the ears!

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[sylverbard[TK]]

Won't the bolts hold the ears in place properly? If they need to be glued just put the bolt through backwards and tighten down until they are in the right spot...id tape the outer ear to protect the glossy white.

 

 

Nevermind. No screws for ei or higher. Wow.

 

Glue , tape across then clamp.

Edited September 26, 2016 by sylverbard

[Maxl[TK]]

Thanks for the tipps.

 

Won't the bolts hold the ears in place properly? If they need to be glued just put the bolt through backwards and tighten down until they are in the right spot...id tape the outer ear to protect the glossy white.


Nevermind. No screws for ei or higher. Wow.

Glue , tape across then clamp.

Yes, I do not have screws/bolts in the ears like Frankenstein

 

After much thinking and trying (repeat) I have finally developed a tactic to clamp the ears.

 

A test on the left side of the helmet:


Under the clamps and the magnets a piece of foam so they cannot "move". A wooden piece with magnets to push down the hollow.

Here the results:

 

I hope it will works, when I start gluing it.

[troopermaster]

That's what I like to see. Improvise, adapt, overcome!

[Maxl[TK]]

Today I finally feel that I have brought on much. One step nearer till to finish the helmet.

Here you can see the lining BEFORE processing:


DURING processing (with saw (!!) and grater):








And the last stand:







Has to be processed again and more. For that I drawed the "ominous lines".

The lining should be ready tomorrow. After that only electricity, ears and the remaining decals have to be mounted. If everything will fit, I only have to paint white the soles of the shoes and then ... hehe ... THEN the   is finished

I expect with "before Helloween", so keep on looking my threat

Edited September 30, 2016 by Maxl

[Maxl[TK]]

A little bit more sanding and the helmet will feel comfortable to carry.

here I glued the foam (which was on the helmet inlay fixed) after sanding:


it actually looks great, ...


... but if you look closer, there should be sand off more 


approximately that much should be trimmed off:


The electric for the helmet is nearly combined. I (hopefully) can order it tomorrow. There is so much to note

I posed a bit with my "new" helmet (couldn't resist):

incognito:


sexy Duckface-Selfie


message: Metal never dies :P

[Maxl[TK]]

The inlay get an upgrade and adjustment:




There's not much left of the inlay and no protection against motorcycle accidents or hammerstrikes

It looks very comfortable...



 

The originally construction was very fine, because you could pull out the inlay and wash if needed. I decided to retain this function and glued a stripe of velcro on the front of the inlay and the filling of the inlay. Now I also can pull it out and wash

The helmet electronic is already ordered (thank you for all ukswrath!!!) and will maybe arrive at wednesday.

I'm very very nervous

[Maxl[TK]]

I did some work at the eyes, because they look awful to me. It's really easy to trim ...

That's how they looked:
right eye

left eye




And that's how they look now!
left eye:








right eye:








Tomorrow I will buy an insect lattice / mosquito net for behind the frown.

[troopermaster]

Great job trimming out the eye sockets!

[Maxl[TK]]

Great job trimming out the eye sockets!

Thank you very much. It was work for two days

 

sent from Deathstar

[Maxl[TK]]

I got the fly net for the frown (of the helmet )




a short meassure (length and wide - approximately 17 x 6 cm) to know where to cut and how much to cut off:








More of the stripes obscure the face of the wearer more (logically )




That's how it looks like from the inside of the helmet. Breathing through it works perfect


And that's how it looks like from the outside (it is already not glued)

[sskunky]

Cut less.

 

You seem to be thinking that that the teeth are cut out from large to small which is a mistake. ROTJ teeth are cut small. Do not follow CFO which are cut hugely incorrect. I will show you how to cut them properly tomorrow/today

I just wanted to point out that contrary to what Paul told you some helmets had the teeth cut out quite large. Again no real rules with ROTJ.....

 

Edited October 23, 2016 by sskunky

[Maxl[TK]]

Alright. Thank you. I'll try to cut out the teeth a bit more before gluing the net.

Merdé.... I have to paint the teeth again.... Hm.....I'll think about it.... :-D

 

sent from Deathstar

[sskunky]

It's personal preference. Same goes for ESB MKII. Some had teeth cut quite large, some small and some not at all!<br><br>

Same with the armour. If you look on the real suits some had overlaps inner over outer and some had outer over inner. Some troopers had detonators a lot didn't. Some had holsters again some didn't. Lots of different variations seen on screen. Shoulder Straps were riveted on but with the grainy film and blurred screen caps it's hard to see. Unfortunately the CRL on ROTJ does not reflect this.

[Maxl[TK]]

Are there any rules regarding the number of rank stripes of the ear bars?

 

Because in the CRL's is written:

 

"Ear bars have only two to three bumps painted in black (rank stripes)"

 

And which two (or three) of the four bumbs shall be painted?

 

AND - which color is the right one? Is it the same grey like the buttons of the control panel on the AB-Plate?

Edited October 29, 2016 by Maxl

[sskunky]

I always thought that ROTJ had two stripes and some of the ESB MKII had three. I haven't seen ROTJ with three? I could be wrong. I'll have a look through my reference pics. <br>

The grey is Humbrol #5 and the black is Humbrol gloss black #21