View Full Version : Casting helmets...

03-05-2001, 09:39 AM
Has anyone ever casted helmets before? I was reading the process at FFURG and it seems pretty easy and cheap to do. I want to make Endor Rebel Helmets so I can do removable helmets for Leia and Luke and make varying Rebel Endor Soldiers.

If you've done it, how easy was it and were the results what you expected?

03-05-2001, 03:28 PM
Cheap? Easy? I'm not sure what method you're thinking of, but I found it to be neither.

I cast in resin, which is expensive initially. You have to buy a lot of stuff to start up. I suppose after that first investment, each helmet would wind up being pretty cheap.

Making molds sounds easy, but it really isn't. There is definitely a lot of trial and error mixed with frustration. Keep in mind that the helmets (particularly pilot helmets) are small and thin - two things that make molding difficult.

I was satisfied with the results, though. Cheaper than buying a bunch of figures just for their helmets, and they look just as good.

03-05-2001, 03:45 PM
What was the expensive part? What I've read is the latex for the mold is cheap ($10) and the epoxy resin for the cast is only a few dollars. Is the the extra stuff you need like the mixing cups, rubber gloves, etc.?

I've never done it before so I have no idea, only going on what I read. Was the epoxy easy to paint? Did you use acrylic or latex paint?

Sorry for all the questions, but I want to be prepared. I think I'll just start with trying to make the molds. If that is successful then i try the casts. That way if I just can't get the molds to work, I won't add the expense of the resin.

03-05-2001, 11:31 PM
Don't take what I said the wrong way. I'm a really cheap guy. To me, $20 is a LOT of money. http://www.collectstarwars.com/ubb/images/icons/smile.gif It's only expensive in the sense that I usually spend less than $3 when I go out for model supplies. http://www.collectstarwars.com/ubb/images/icons/smile.gif

I found it very easy to paint, and I used acrylic paints.

I think your idea of starting with the molds is sound. I would recommend starting by making molds of generic shapes. Make a mold of a cube, sphere, pyramid, etc. to get the idea behind different techniques. Not every mold can be done with the latex stuff. Sometimes you need to make a two-part mold which is a lot trickier. I actually stopped by my university book store and got a reference for doing some of these things, which helped save a great deal of frustration.

More than anything, have fun. http://www.collectstarwars.com/ubb/images/icons/smile.gif

09-13-2003, 08:14 AM
I found a website that sells custom asted accessories and they are selling Endor Rebel soldier Helmets the name here is the link toJ&R (http://www.zfactor.org/jandrcustoms/index.php?page=catalog&id=c-clhht-01) that might help if you are still looking for helmets.

09-13-2003, 11:01 AM
Casting can be expensive, and what one considers easy or not is relative I suppose.

The articles at FFURG are good to start out with, but if you're looking for long-term projects or mass projects they're not the best way to go.

Buying professional casting equipment will cost you something... It is pricey to me personally (but worth it for me too) to be able to buy urethane RTV mold rubbers and multiple consistencies of resins.

Some resins are more complex to use than others... Others are fairly simple.

The articles we have over at www.ffurg.com (http://www.ffurg.com) generally are talking about the cheapest way possible to make a mold, and using things like the epoxy are "alternatives" to buying professional grade resin (Epoxy is NOT resin, they're different products all together).

I'd suggest tinkering with the methods at FFURG first, as they're not going to cost you for mistakes. Often times then, you can get a fairly inexpensive "starter kit" for casting on a more high quality level...

Some things will always be complex (or even possibly impossible) to cast... The Endor helmet would, IMO, be a toughie to get exactly copied like it looks without some special equipment, but it may be possible. Give it a try using some of our articles up at FFURG and see what results you come up with! images/icons/smile.gif