Home of the Sovereign Protectors

Thanks for all the compliments on this build so far.

I am about to start sanding utilizing 800-grit sandpaper. Getting near the finish line with all of the sanding. I can see the light at the end of the tunnel that is the final paint job. Since I'll need to sand / shape the eye slot opening in the helmet, I went ahead and finally cut it out. I used the large and small sanding wheel to take off a majority of the material and got into the corners using a thin cutting wheel on a low setting.

I can finally see out of this thing. Looks like it will be a very "open" 180 degree view.

I smoothed out the cut I made around the eye slit by knocking the ABS down using 220-grit paper on the edges. In only a few minutes, I got a pretty level look to the opening. Then I quickly went around the edge of opening with 400 & 800 grit sandpaper.



You'll notice the spot putty around the top of the eye slot. My Dremel gently brushed up against the surface and caused a ding in the ABS. Simple fix.

Before I get my helmet painted at the end of December, I wanted to make sure my visor was cut to size / shape and pre-installed inside of the helmet.

Unfortunately, the "gasmonkey" kit that I bought is amazing BUT it DOES NOT come with visor material. The RotJ Guard CRL calls for red or charcoal tinted visors. I began my search and found a nice precut Guard visor from FenixProps but he wanted way too much money for the visor + shipping costs from Argentina. After searching and searching the good 'ole interweb, and various forums to no avail about what to do for a visor, I got the advice from a member on 501st forums to use a particular charcoal face shield mask and custom make the visor. What I had planned on doing anyhow but couldn't find the charcoal faceshield until he showed me the right online store to buy it from. I ordered this faceshield (which comes with clear and charcoal shields) for only $20.67 after shipping. Should be exactly what I need. It should arrive just before Christmas. Which is perfect so that I can fabricate the visor before sending it to my local buddy to professionally paint for me.

Now to figure out which method I want to use to attach it with.

Good to hear of the great teamwork on your build.

Received this grinding face shield to make Guard visor. Took some searching but finally found it online. Was $20 for full grinding face shield kit but it comes with head piece which I don't need and a clear & dark charcoal plastic visor. Now to cut them to shape. I could probably make 3-4 visors from this material. Maybe more.

I'm thinking of installing mine with Velcro. Like recommended to me on Sovereign Protectors forum. That way, I can switch them out. I read for daytime troops, people use charcoal lenses & night time troops people use red lenses. I could cover the clear visor with red tint perhaps.

Now that I have some free time after the holidays, I will now begin to fabricate a visor from scratch, before I send my helmet off to be painted.

I began by holding some cardstock to the inside of the helmet visor opening. Holding it as close to the top edge as I could. While holding the cardstock flush along the entire opening, I had my wife help me trace the visor opening edges.


I then took a ruler and added roughly 1cm all around the traced lines to help with visor placement and to allow for cover. I will trim as required once I finalize placement.


Now to cut the cardstock template and transfer it to the face shield material. The way the helmet is on the inside there isn't much area at all to assemble the finished visor to the inside. I'm going to have to fabricate some sort of system utilizing earth magnets to hold the visor in place. That's the plan anyhow. More on that later. I'll install final visor once the helmet is painted.

Good luck. Hope all works out.

You can also use red wrapping film to place on top of the visor to give it a red tint.

LuciousTalvloinne wrote:You can also use red wrapping film to place on top of the visor to give it a red tint.

Thanks. I'm going to make 2 visors. The clear visor I'm going to add red tint to and then the 2nd visor i'll have will be the charcoal. It's pretty dark though and kinda hard to see out of when indoors.

I really need to get back to it on this build. Been taking the past month of from building it. Helmet is ready for paint and I'm about to buy my fabric for the robes

Would love to see a tutorial on your Visor assembly.