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Forest trooper Profile
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Registered: 11-2012
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C-3PO head rebuild


I bought one of Jim's[Starbuckcylon] vacformed helmets and this wee tweak job has turned into a big job emoticon

The helmet shape has been changed, chin, top, sides etc remade.

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The eyes have been made a bit bigger diameter, thicker sides and some other changes. I made them on the SLS machine in work out of nylon, they are painted grey primer atm.

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1/9/2013, 5:48 pm Link to this post Send Email to Forest trooper   Send PM to Forest trooper Blog
 
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Re: C-3PO head rebuild


Looking great! Very nice work.

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Re: C-3PO head rebuild


Good job

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1/10/2013, 9:48 am Link to this post Send Email to cymico   Send PM to cymico Blog
 
Forest trooper Profile
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Re: C-3PO head rebuild


Thanks guys, I am nearing the stage where the faceplate fits the rear of the helmet. I can't find great pics of an original and exactly how it slots, overlaps or what. All help appreciated. emoticon
1/17/2013, 5:34 pm Link to this post Send Email to Forest trooper   Send PM to Forest trooper Blog
 
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Re: C-3PO head rebuild


http://lotinlife.files.wordpress.com/2012/02/dsc02940.jpg

here is a simple sketch of how I did it. Unfortunately, I do not have any pictures of the actual results.

Using masking tape I masked off the areas where my "registration tabs" would go (two on each side of the head*, one on the top and two where the neck bolts go through). Then I used masking tape to keep the two halves together in the correct closed position.

Then I put layers of fiberglass over this area. When everything is dry, remove the masking tape and separate the two halves. Some trimming work is needed to make a nice profile out of those tabs.

I hope this helps you out.

* The reason I kept the tabs so small was because I was planning to wear the helmet. Because of my face, the face plate would expand/flex. If the tabs would have been made covering a larger area, I would risk it cracking or separating from the ABS helmet due to the stresses causes by the front expanding.

Last edited by littledragon88, 1/18/2013, 3:04 am


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Forest trooper Profile
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Re: C-3PO head rebuild


Thanks Little dragon, I have seen your blog, nice read, however I am wanting some pics of any of the original heads and how they were done. I have looked at lots of pictures but this part is never photographed well. And of course the wee eye bracket on the top of the mask.
1/18/2013, 12:48 pm Link to this post Send Email to Forest trooper   Send PM to Forest trooper Blog
 
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Re: C-3PO head rebuild


Sorry the pics are rubbish, Blackberry phone, I have tried to get the lines tidier, some more primer,a bit more sanding and painting of the eyes and a quick fitting of the brass antenna and neck bolts[thanks Eco/Paul].

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1/18/2013, 5:44 pm Link to this post Send Email to Forest trooper   Send PM to Forest trooper Blog
 
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Re: C-3PO head rebuild


Wow, your retouched helmet is fantastic! I love the sharp details!

If you didn't tell me it was an ABS helmet, I'd thought it was a Zorg fiberglass helmet! emoticon

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Re: C-3PO head rebuild


Image

Here's the inside of a (screen used?) helmet I found through a quick google-search.

Last edited by littledragon88, 1/18/2013, 7:39 pm


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Forest trooper Profile
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Re: C-3PO head rebuild


Thanks Little dragon, still a lot of finishing to do yet, the back slots need to be filled slightly. If I am not mistaken the original slots seem to have been cut out with a wheel. Mine are a bit deep atm. Two pack high build primer is great for sanding a sharp edge.
My helmet is quite a bit wider and longer than it was originally, eyes are very slightly bigger, hopefully they will look better once they are the same colour as the head. The inner size is smaller than Jim's version, with the lights fitted I hope they don't look too small.

Thanks for the help, yes I have seen this pic. I have googled, checked the brilliant reference pics here and looked up many fan pages trying to get decent pics of the back edge of the faceplate. Nothing clear enough.

   
   
1/19/2013, 7:25 am Link to this post Send Email to Forest trooper   Send PM to Forest trooper Blog
 


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