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  1. #1
    DF PwNagE beerman's Avatar
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    Default Stormtrooper helmet

    Lots of filling and sanding to do and I still need to reprint part 16 which is around the back at the bottom. I misaligned it on the print bed and as a result it chopped around 1cm off the edge. The printer thought it wasn't within it's limits to didn't go any further.
    Some of the parts warped slightly so the fit isn't the best. Saying that the gaps look a lot worse in the photo than when I run my finger over them.

    Last edited by beerman; 9th July 2017 at 08:19 PM.

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  2. #2
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    Default Re: Stormtrooper helmet

    thats pretty cool mate, how many pieces all together?
    You know he grew up as a little shitspark from the old shitflint and then he turned into a shitbonfire and driven by the winds of his monumental ignorance he turned into a raging shitfirestorm. If I get to be married to Barb I'll have total control of Sunnyvale and then I can unleash the shitnami tidal wave that will engulf Ricky and extinguish his shitflames forever. And with any luck he'll drown in the undershit of that wave. Shitwaves.

  3. #3
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    It's 16 main pieces and a few small accessories. It took 92 hours in total (not including a few failed pieces along the way). I used around a kilo and a half of filament printing at 20% infill.

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  4. #4
    DF PwNagE Mobileman's Avatar
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    Default Re: Stormtrooper helmet

    What reckon it cost you to do just in materials mate , excluding wear tear and time


    Sent from my iPhone using Tapatalk

  5. #5
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    About £30 on materials and whatever 92 hours at around 150 watts in electric is. I know I can go on aliexpress and buy one for £60 but where's the fun in that?

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  6. #6
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    I used some expoxy on the inside around all the joins and it seems quite rigid now. I even dropped it by accident and it just bounced.

    The first fill and sand is done. I need to go back over the teeth and the brim around the helmet but the rest is pretty smooth. I only have 240 grit sand paper so might have to get some with a higher grit to finish it.



    When I fitted the last piece at the back there was a 6mm gap left which I've had to fill. I built it up with epoxy and then used some filler. (The bit at the bottom)


    And what it looks like now.
    Last edited by beerman; 9th July 2017 at 08:22 PM.

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  7. #7
    DF VIP Member Bald Bouncer's Avatar
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    Default Re: Stormtrooper helmet

    Quote Originally Posted by beerman View Post
    The first fill and sand is done. I need to go back over the teeth and the brim around the helmet but the rest is pretty smooth. I only have 240 grit sand paper so might have to get some with a higher grit to finish it.
    You can always use toothpaste if you have already gone to 240 grit

    [Only registered and activated users can see links. ]

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  8. #8
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    2nd pass for filling and sanding. I rebuilt the brow and teeth.


    The teeth still aren't perfect but I think it's as good as I'm going to get them.

    The ears are tricky too. They probably need another pass.


    I'm having a few troubles with air bubbles in the filler.


    Will probably pop down the shops in a bit to grab some filler primer. I'll see then how good my sanding skills are
    Last edited by beerman; 9th July 2017 at 08:56 PM.

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  9. #9
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    My initial thought after adding primer is wow I need to do a lot more sanding.



    Last edited by beerman; 9th July 2017 at 08:23 PM.

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  10. #10
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    Sooooo....I dropped it



    For some reason I missed the epoxy on that section so it was only superglued. I've added some more epoxy and filled it along with the bits I thought were smooth. Oh well, I was hoping to get it finished this weekend.

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  11. #11
    DF Super Moderator Over Carl's Avatar
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    Default Re: Stormtrooper helmet

    Little tip you might find handy, get some filler primer.

    It's like normal primer but much thicker, however it is very easy to sand down. I don't know why, but I've only ever found filler primer in dark yellow/orange.

    Idea is you can use this to hide small imperfections but instead of filling and sanding, then priming and sanding, now you just prime and sand.

    I don't know why, a lot of shops that sell car paint don't do filler primer though so might take a bit of time hunting some down.

    Thanks to Over Carl

    beerman (9th July 2017) 


  12. #12
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    That's exactly what I bought from a local motor discount place earlier today. Along with some white and a black colour brush. I've filled and sanded it down again and it's just been primed again in the garden.

    The dome is easy to get smooth, the finer details are a real bitch.

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    Over Carl (2nd July 2017) 


  13. #13
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    Perspex turn up today for the eyes. 3mm dark green tint.

    I printed some extra eye sockets so I didn't have to piss about trying to fit them in the helmet whilst hot.

    There are fresh from the oven at 150 degrees c. Just enough to get the perspex malleable. Then I used a spoon to push them tight to get the shape.



    The top one came out better so will probably warm up the perspex and do the bottom one again.
    Last edited by beerman; 9th July 2017 at 08:57 PM.

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  14. #14
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    Managed to get the first coat done today too. Spraying in this heat the spray pretty much dries before it gets to the helmet and leaves a coarse dust. I ran out of spray before I managed to get a nice coat on the top and under the tubes so I'll grab some more tomorrow.

    I also cut up the rest of the foam from my 3d printer packaging and shaped it which I intend to hot glue to the inside.


    I found a template for the tube strips, can anyone print and cut vinyl on here? Otherwise I'll be cutting them out with a blade and hoping the paint doesn't creep underneath. If they were straight I could just mask them off with tape but they are curved.

    This is an early pic of the foam, it's a lot more "foamy" in there now.
    Last edited by beerman; 8th July 2017 at 01:45 AM.

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  15. #15
    DF Super Moderator Over Carl's Avatar
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    Default Re: Stormtrooper helmet

    Quote Originally Posted by beerman View Post
    Spraying in this heat the spray pretty much dries before it gets to the helmet and leaves a coarse dust.
    Very fine wet and dry (1600/2000) can get a dusty finish smooth and shiny.

  16. #16
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    Started making the details whilst it's too hot to spray, although I may get another coat done later tonight if it cools down a bit.

    The original mic tips that came with the helmet design were 3d sculpted and looked shit so I made these. They are as accurate to the screen helmets as I could get them. I found a page with the dimensions ([Only registered and activated users can see links. ]). I printed them in white and then painted the outside black. The mesh is from an old camping pan I found in the shed.



    I need to redo the mesh in the top one but you get the idea. Not sure I like them as they are black and the on screen ones are silver so may get some coarse pipe mesh.

    I ordered some Humbrol black enamel for the brim as the black I have at the moment it way too thick to spread across a large area, it was bad enough painting the mic tips and will be quite hard to get some good lines when painting the details on the helmet. I also ordered some midnight blue for the tube stripes.
    Last edited by beerman; 8th July 2017 at 01:46 AM.

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  17. #17
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    Wow looks like photobucket just fucked me over like they did bertroot.
    I've uploaded them to imgur for now. When I get a chance I'll change the photobucket links

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    Over Carl (9th July 2017) 


  18. #18
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    Wow looks like photobucket just fucked me over like they did bertroot.
    I've uploaded them to imgur for now. When I get a chance I'll change the photobucket links

  19. #19
    DF PwNagE beerman's Avatar
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    Default Re: Stormtrooper helmet

    As a test of imgur this is after 3 coats. Will probably do one or two more coats then a few clear coats after the detailing is done.

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  20. #20
    DF PwNagE WRATH OF BOD's Avatar
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    Default Re: Stormtrooper helmet

    looking great Beerman, i spotted this today and fancy trying it

    How-To Make Metal: Electroplating a 3D Printed Star Wars Helmet
    Last edited by WRATH OF BOD; 7th July 2017 at 11:14 PM.

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