RS Prop Masters

Vern bro, the Stunt helmet is a khaki green smooth hdpe (or that family) plastic. The heros are ABS, smooth I am sure. Pinseal ABS was used for ROTJ and ESB 'new parts'. All the ANH armour was 1.5mm gloss abs, now was it ALL painted.................thats another question.

A true gent, the name says it all.

Interestingly, the delail on the very bumpy ESB helmet, on the front of the frown, on its left side, is also present on Simons original, but it is much more pronounced on the ESB one, its pretty small on Simons. You could be correct about the tempeature, I can see how that is possible and very likely thinking about it

Paul, You missed my point (I think) I think the issue could have been dirty hdpe and maybe to a lesser extent the moulds. As for the mould construction, we dont know who made the moulds, was it AA or was it the studio? Were they metal filled, epoxy, or just polyester? I agree AA was a vac commercial vac former at that time, with a large machine or machiness, but that in no way sugests he was a pattern/tool maker. Would be good to compare the brush marks inside the helmets, or the ones visible on the outer. I will get some photos of the clearest ones I can find and we can compare to see if they are unique to a helmet or consistant. Its an intersting point you raise on the temperature, it would of course be possible that some kind of reaction could happen, hard to rule it out not knowing what the moulds were made of. A cleaned up helmet would not really have the same character imho, as we believe that all the stunt helmets had these imperfections then thats the prop, maybe not the intended sculpt, but the finished prop nevertheless. On a side note, I am pretty sure the bump is present on the set for stun helmet, its on the mini ones that were produced, well its on mine.

Yeah, the bumps are a definite texture inside the helmets. I am sure the one you have highlighted is a present on the tool. Maybe some of the other texture can be explained by being present on the plastic underside before forming. The material, to make ponds as AA tells it, is more of an industrial plastic and is not supplied with any protective films etc. It if is formed with dirt and dust on it, between the plastic and the tool it will be present on the pulled piece. Also, when formed the front of the back and cap will naturally stretch and thin more than most of the other areas on the piece, thus showing more imperfections.  The inside of the helmet has what can only be described as brush strokes inside. I asked Brian Muir if this could ever have come from the sculpt or mould, he thought it was extremely unlikely it was from the sculpt, as a brush wa not used to finish the clay, but it was possible (but unlikely) it was from the gel coat of the tools. Maybe, thinking about it the brush strokes atre from cleaning the plastic. When puling the HDPE type of plastic it forms like a liquid so tightly to the tool and collects EVERY detail, details that ABS or even HIPS will not pick up, its an interesting plastic. As to the question about the gouge noticed inthe ESB helmet, no, its not present, maybe tool damage after Simons lid was pulled. Rob.Â

I don't think the cover was fully replaced, just fastened back down. It's not a huge difference, most likely a cutting error, as they are both uniformally the same width top to bottom. I think it just show how they were put together quickly. Hey Paul, so we're the gloves cut down, or is it bunched up? My gloves tuck in, but trimming the excess would make sense.

.........he has not been shy trimming that left forearm either

That is an interesting trim line. How sure are you it is not his under suit bunching up over the armour? Just a thought

Hey guys. So we got a little time to build up a screen spec suit. We thought we should share the process. OK, the Right Thigh. This has been reported back to us as a problem area, so here is how it goes together. Here we see the top. ...and the bottom. Note how it is miss-aligned, about 8mm, but there is quite a bit of filler/glue around the area on the original. Gluing the cover strip to the first edge, the original used for reference. Here we can see the miss-alignment on the original and replica. Also note the addition of a small piece of ABS to the raised detail section join from the inside. Here is how I cut the knee ammo belt corners, right off the screen used suit. You can also see the inside of the rivet here too. and heres the almost finished part. Left Leg. Here we have the front cut to size, for the cover strip. This one is a little more straight forward. Both together. Interesting to note that on this set the cover strip on the right is 24mm and 22mm on the left.

Can't really see the point to be honest.........if it's not broke..........but dude, if it floats your boat

Are the camping ones the "Anorak" type? If so, not really, but you get the setting tools in the kit. I have some spare if you need them?

Looking great so far. Jesse, what's the depth achieved on the drop boxes and end caps? If you need replacement parts let me know brother.

The first photo, lit from above really highlight the imperfections that are present. Love it!

Loving it bro.

I will get a comparison of the original and replica up soon guys. We are supplying holsters with suits currently, due to the work load with Alison

Hi guys I thought it would be nice to share some photos and information about the Stormtrooper belt. The original belt is made from a number of laminated layers of different fabrics and stitched together around the edge. The outer layer is known to be a canvas, which is how most replicas are constructed. Here we can see the layers. The inner fabric is a satin type and shiny. Strange that the inner most side would be shiny, maybe they were originally made to have this fabric to the outer? I can't see a reason why else this would have been made in this way. The replica show in the photos is made by Clothears Costumes for us. They took the belt away and came back a few weeks later with a knockout replica belt and holster (more to come on that later). They absolutely nailed the details, matching every layers fabric type and weave. Staggering, but I expected nothing less from these guys. RS

Rolf, if your enthusiasm was building these suits, they would both be done already

Guys, you are making me blush. It was a no brainer! OK, just a little back story, whilst at the event, with The Dented helmet and RPF I was chatting away when I was told some one wanted a price for a helmet. So I gave the info, unaware of the situation or knowing it was for the guys ill child. Later when I found out i felt like the biggest c**t. So I was truly happy to be able to supply a helmet kit, if I had of know the situation I would have offered anyway. Thanks to Gary for following it up and un-c**tting me Dan, Luke, really, I got to see that!

Have a good one Ricky!

Loving the build. Nice helmet choice too

Looking sweet. Great work.

Looking very nice buddy.

Hey guys, looking great so far. No, I don't use the holes either. It is not 100 clear on th back and cap where to drill, so I ignore them and build as I like the look. The original holes were drilled from different angles and not straight in, which can throw it off a little. That said, the holes I end up drilling are not far out by the time you have it finished. I have a step by step of building a lid I will post up as soon as poss. Rob.

Cleaning armour, Really? Well, I guess if I trusted my wife with my suits maybe . Man, I don't even wash my Boba Flight suit, that weathering and lived in look is part of it all. After troopin it time for Rob.

Once the belt is on tight it is should help bend that ab to your body shape.