JS1 Posted May 23, 2017 Report Share Posted May 23, 2017 Hi all, I like to start a new build thread for my ANH stunt stormtrooper. Hope to have a Centurion level armour quality set at the end of the build .. no clue yet how I will be able to achieve this though. So much to learn ! The set I bought came from RS Prop Master when they had their 40 years celebration kits for sale for an attractive price. I have the helmet and armour + strapping kit and ordered also the blaster, holster, 2 piece suit, shoes and neck seal. These are not yet delivered. I already have build the helmet and will start this build thread with the helmet first. Looking forward to all your comments so I can submit the costume for 501 approval ! Thanks Johan 1 Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 When everything arrived is was rather overwhelming.. the box with armour and strapping kit 1 Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 The helmet .. just a few pieces. 1 Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 This is really an awesome piece to build, directly casted from an original ANH helmet and showing all the original wrinkles and bubbles and inaccuracies of the original prop. The helmet is also build in exactly the same way as the prop making it's assembly a real journey back to 1977 ! The only real difference is the material used. ANH screen used helmets were made from HDPE painted white. Armour was made from ABS. In this thread I will just post how I assembled the helmet. It is a first time build, so probably there are so many other and better ways to build a helmet. Some of the tools I used : 1 Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 At each side of the front face plate, some plastic needs to be cut away to install the black rubber ’S’ brow trim. Here the 'before' photo, then the 'after' photo. The brow line ,needs to be trimmed as well to make it more or less horizontal. Trim little bits at a time until it fits nicely. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 Black leather brown trim installed. Then drill two holes in the front faceplate Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 Instead of rivets, I 'm going to use some screws to attach the faceplate to the backplate. These can be later replace using rivets or not ... Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 Allign the faceplace and the back as seen on this photo, mark one hole on the backplate at one side only and install the screw. Ensure the other side in aligned, drill a second hole in the blackplate and again install the screw. Fitting the helmet to the face (with the brow trim in place) is is important to give a balanced look. There should not be a gap in the brow line between the face and cap and the cap should be centered onto the face. When all is fine, you can replace the screws with a rivet, but ensure using a backing washer on the inside as the rivets will rip right through the ABS plastic. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 Remove some excess plastic under the ears. I fitted the ear temporarily and marked with a pencil some plastic which can be removed. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 Use of an additional screw at each side to fix the two plates together. As long as both screws (or rivets) are under the ears, one can do whatever one wants. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 It now already looks like a helmet Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 The left and right ear are already partly cut by removing the excess ABS around the ears. The next step is cutting them so they match the curved helmet surface. In my opinion, the most tricky part of the build. I would leave way more ABS material than you think you'll need when making your first cuts.When installed on the helmet, ear gaps are authentic and seen on all screen used helmets, but one should not overdo this. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 Two holes were drilled in each ear. The location of the hole was already marked onto the plastic. ANH stunt helmets will have three screws, hero helmets just two. This will become a stunt ... Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 23, 2017 Author Report Share Posted May 23, 2017 Dry fit of one of the ears. Not many plastic was cut beforehand. Fitting the ear shows were more plastic should be removed. Do this slowly and patiently, step by step, cutting small amount at a time, fitting again, cutting, fitting, etc... Don't cut to much !!! Quote Link to comment Share on other sites More sharing options...
Risvang[501st] Posted May 23, 2017 Report Share Posted May 23, 2017 Looking good. Remember measure twice, cut once. Sent from my iPhone using Tapatalk Quote Link to comment Share on other sites More sharing options...
Shanester[TK] Posted May 23, 2017 Report Share Posted May 23, 2017 Keep up the good work! Ask questions and read other build threads. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 The black S-trim can or cannot overlap the bottom edge of the ears a little. Screen-used helmets exist where the bottom of the ear is within the S-trim and where it is above it, so either is fine. When installing the S-trim, ensure it is a bit longer (approx 2.5cm) than the circumference of the opening to allow compression force to help keep it in place. In this case I have not trimmed the underside of the neck opening. If one do so, do the trimming after the ears were installed. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 The foam liner was cut and installed in the helmet. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 Eyes were cut out with a knife. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 Drill two homes for the Hovi-Mix mic tip greeblies. The mesh front inserts will be installed after painting these black. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 Humbroll paint needed, numbers 85, 14 and 23. One also needs gloss white for painting the visible screws. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 For a ANH helmet, all details were hand painted, ie. the trap detailing, tube stripes, frown and vicoder. ESB movie helmets were finished with decals for the traps and tube stripes with painted frown and vicoder. This helmet will be finished as an ANH version, so no decals will be used. However, in order to have an accurate template, I printed all the decals on a sheet of A4 paper, cut them out so they can be placed onto the helmet. paper decal put on the helmet to allow to mark the shape with pencil. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 Using a pencil, I first outlined the area of the detail to paint onto the helmet. Quote Link to comment Share on other sites More sharing options...
JS1 Posted May 24, 2017 Author Report Share Posted May 24, 2017 Painting the details, one need 2-3 layers of paint to have a good coverage. Some WIP photos Quote Link to comment Share on other sites More sharing options...
MrSnrub[501st] Posted May 25, 2017 Report Share Posted May 25, 2017 I dont think your suppose to cut out the 5th tooth,but im pretty sure one or two troopers had it in the film Quote Link to comment Share on other sites More sharing options...
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