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ROTJ reinforcement for Austria & the Empire


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Me too :D

Works perfect but stinks like hell for ages!

 

:D

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

Edited by Maxl
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:D

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.

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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.

DSC_0186_zps1fkok27m.jpg

 

DSC_0188_zpsoaz0qquq.jpg

 

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

DSC_0193_zpsrjmbk0nh.jpg

 

DSC_0194_zpsvraeydxk.jpg

 

DSC_0195_zpsumu1p4sj.jpg

 

DSC_0196_zpszn62ujx5.jpg

 

DSC_0189_zpsrjxfml76.jpg

 

DSC_0190_zpsbhqzukuf.jpg

 

DSC_0191_zpssh4fxgqm.jpg

 

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

DSC_0197_zps8cj1zkxe.jpg

 

many times cutting and test fitting again and again ... :huh::)

DSC_0198_zpszrndlw3k.jpg

 

DSC_0199_zpsyvczlori.jpg

 

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

DSC_0200_zpsqanykts7.jpg

 

DSC_0201_zpsnu5amdxe.jpg

 

more pictures will follow ... till then ... cu! :salute:  ;)

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Lovely

 

Sent from my HTC One_M8 using Tapatalk

 

Thank you! :duim:

 

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

 

DSC_0203_zpsxrlydhog.jpg

 

DSC_0204_zpsmhidzabl.jpg

 

DSC_0205_zps7oydv8ab.jpg

 

DSC_0206_zpsxcuz6gez.jpg

 

DSC_0207_zpsaeqsoaso.jpg

 

DSC_0208_zpsbsienz2r.jpg

 

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 :mellow:

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

But all anticipated here the operation:

First roughly mark and cut:
DSC_0209_zpsv0q5bgyh.jpg

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 ... :duimomlaag::blink: )

DSC_0210_zpsjx4oryvk.jpg

DSC_0211_zpsoe2nvqjj.jpg

DSC_0212_zpsa8lgpico.jpg

DSC_0213_zpsfbqkr6m1.jpg

DSC_0214_zps7yjamrld.jpg

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 ... :blink:  I don't know HOW to clamp!!!!! Can anybody help me, please?

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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 by sylverbard
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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 :P

 

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:

DSC_0216_zpsd87pqqjz.jpg
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:
DSC_0218_zpsd4a5rpho.jpg

DSC_0219_zpsxm8st1yg.jpg

DSC_0220_zps5c9ydchm.jpg

DSC_0221_zpspifzk69n.jpg

 

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

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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:
DSC_0233_zpsnm1szvmw.jpg

DURING processing (with saw (!!) and grater):
DSC_0224_zpssp8sfh5i.jpg

DSC_0225_zpsci3gfuql.jpg

DSC_0226_zpsqnkrk5ty.jpg

DSC_0227_zpshbvwastb.jpg

And the last stand:
DSC_0228_zpsjsmfpuct.jpg

DSC_0229_zpskfkhymmg.jpg

DSC_0230_zpsiqajwntz.jpg

DSC_0231_zpsnveze6ab.jpg
Has to be processed again and more. For that I drawed the "ominous lines". :D

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 :smiley-sw013:  is finished B)

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

Edited by Maxl
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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:
DSC_0234_zpssvd7pa19.jpg

it actually looks great, ...
DSC_0239_zpstrgzr20u.jpg

... but if you look closer, there should be sand off more  :glare:
DSC_0240_zpsdxao5w8q.jpg

approximately that much should be trimmed off:
DSC_0241_zpsuuz71pht.jpg

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

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

incognito:
DSC_6689_zpsrggsb064.jpg

sexy Duckface-Selfie
DSC_6690_zpsg6prsnuc.jpg

message: Metal never dies :P :P
DSC_6691_zps40cap9wr.jpg

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The inlay get an upgrade and adjustment:
DSC_0242_zps1jvdsqws.jpg

DSC_0243_zpsyeymw9aj.jpg

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

It looks very comfortable...
DSC_0244_zpsvnatmyim.jpg

DSC_0245_zpswblmza78.jpg
 

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 :duim:

DSC_0246_zpswr7zpkme.jpg

DSC_0247_zpsboyftfki.jpg

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

I'm very very nervous :mellow:

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

That's how they looked:
right eye
DSC_0131_zpswl3hh5y4.jpg

DSC_0132_zps8xruv2bf.jpg

left eye
DSC_0133_zpsuxwqwf8v.jpg

DSC_0134_zpsbewgqgeo.jpg

And that's how they look now!
left eye:
DSC_0248_zps4u8tqguu.jpg

DSC_0249_zpsxcrv5ex9.jpg

DSC_0250_zpss7u0fntg.jpg

DSC_0251_zps5xwaxydy.jpg

right eye:
DSC_0253_zpssfq0a1dd.jpg

DSC_0254_zpso9yyfdmv.jpg

DSC_0255_zpseb94bgpk.jpg

DSC_0257_zpststtoryj.jpg

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

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I got the fly net for the frown (of the helmet :) )
DSC_0262_zpsjcmcwola.jpg

DSC_0263_zpsiviefmjd.jpg

a short meassure (length and wide - approximately 17 x 6 cm) to know where to cut and how much to cut off:
DSC_0264_zpsnxhcl2tq.jpg

DSC_0265_zpsfxeqlebp.jpg

DSC_0266_zpsyds4qjv7.jpg

DSC_0267_zps315zatwr.jpg

More of the stripes obscure the face of the wearer more (logically :P )
DSC_0268_zpskjokgde8.jpg

DSC_0269_zpskeytyaih.jpg

That's how it looks like from the inside of the helmet. Breathing through it works perfect :)
DSC_0270_zps4rbxvkbg.jpg

And that's how it looks like from the outside (it is already not glued)
DSC_0271_zps1lhxrzlb.jpg

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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 :P

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..... :D

 

Dave_Mandell_RotJ_20_zpsfoq0xga5.jpg

Dave_Mandell_RotJ_15_zpsyk14knht.jpg

Dave_Mandell_RotJ_19_zpsvnx6ei09.jpg

Edited by sskunky
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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

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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.

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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 by Maxl
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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

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