cooldevo's ROTJ WIP

[cooldevo]

I meet with the seamstress for the initial fitting tomorrow, getting quite excited to get it started.

Been doing a good bit of work on the helmet, in the meantime. Took a lot longer to do, as it was the first time I've ever worked with ABS in any way. Cut out the visor opening, and trimmed off most of the excess from around it. Gave it a good sanding with 180-grit wet/dry sand paper. I picked up a number of 1/2" rare earth magnets, and was recommended to pick up Gorilla super glue. Still doing a number of dry runs with the clamps and magnets to try and get it set up and done up tight before actually putting the super glue on it. Also trying to work out how to use/cut the ABS strips that came with the kit to reinforce the side seams.

Anyways, here's my progress since opening the box.

[cooldevo]

One question in regards to the helmet. Does the inside need to be painted as well? Currently I haven't sanded it, and it's a shiny black. The part along the bottom that sits on the shoulders I did sand, and was going to paint for sure... but does the inside where the head goes also need to be painted red?

[LuciousTalvloinne]

No the helmet does not need to be painted on the inside at all.

[cooldevo]

Will be gluing the helmet together this weekend, and then applying epoxy putty, and bondo.

As an aside on the Force Pike, I've scrapped what I've done to this point. Found a good deal on aluminum ski poles at a shop near my house. They even offered to remove all the extra parts and strip the pain down to the aluminum for $15. Couldn't say no to that so I'm chainging my plan up.

More photos to follow once I get the helmet glued and pick up my skis that will be already prepped and stripped for me on Friday.

[LuciousTalvloinne]

At that pricepoint for them to strip it down to the base is really a good deal. Great find on that for sure.

[Sascha_Wilsing]

That sounds great. We are interested in watching xour further progress. Thanks for sharing.

[cooldevo]

So... magnets, clamps, and tape came off the helmet last night. Probably left it all on longer than needed, but I figure better safe than sorry. @Khro was amazing getting it glued together. Trimmed of a bit of the flashing, and started cutting and roughing up where I'll be gluing the support strips onto the helmet to reinforce the seam. Tonight will be taking off more glue flashing, and actually heat and shape the strips to form and glue into place.





And last but not least, the first official try on with the newly glued helmet.

[LuciousTalvloinne]

Great Photos. Always great to see family members being supportive in the hobby we do.

[Sascha_Wilsing]

Thank you for sharing the great pictures of your WIP.

[cooldevo]

Three minor updates.

1) Ordered a serrated rasp emitter and tip from Cabbagefarmer to go with the pole parts I already have.

2) Force pike pole is mostly ready. May get some higher grit sandpaper and polish it depending on what the parts from #1 looks like


3) The support strips have been heated until soft, formed over the seam, and the glue with ABS concrete on the inside of the helmet. I'll let it cure tonight into tomorrow and then get the flexible plastic surgery started to fill the seam. An embossing heat gun that my wife had for crafting worked perfectly to soften up the ABS strips that I had cut.


Edit: Updated a broken photo link.