Sunday, April 28, 2013

New York JETS Stormtrooper Helmet

I'd like to dedicate this posting to a number of very important people in my life.
First of all my Grandfather Roger Heneberry (May he rest in peace).

I'd also like to dedicate this to my Uncle Barry. 

 Both my Uncle and my Grandfather were big New York Jets fans.  I'd like to also dedicate this to my girlfriend Jess, who is also a big Jets fan, and supports all my silly projects, even though our apartment has become overridden with helmets and fake weapons.  

And Lastly I dedicate my family who made me the creative person I am today.  Unfortunately I do not have a photo of everyone together.

Shortly after I finished restoring my stormtrooper helmet (seen here), I ordered a cheap $20 stormtrooper helmet off of - which looked like this on the website...

I thought this was an inferior helmet - one that I would enjoy restoring into something a lot better looking. I received my Amazon order only to find out it was the same exact helmet I had just finished restoring.

My restored helmet is on the far left and the new helmet is on the right.

Since I already have a good stormtrooper helmet I contemplated making this helmet into a sandtrooper helmet...

...or a Magmatrooper helmet...

...or some kind of steampunked helmet.

...but I decided to make it into a NY Jets Stormtrooper Helmet to honor my loved ones.

My first step was to take off all the cheap stickers.

Then, using some masking tape, I created lines that ran from the front of the helmet to the back of the helmet - just like a Jets helmet does.

Then I started painting on green acrylic paint.

Anything that was a different color than white received a coating of green paint.

When the paint dried I removed the masking tape.

The helmet still needs several more coatings of green, but while the most recent application dried, I decided to work on the Jets logo which is on both sides of the helmet.

I grabbed the logo from the internet and scaled it to fit on my helmet.  I then printed it out.

Then I put on some thin transfer tape to the back of the print out.

Next I cut out the logo, peeled off the tape cover...

...and stuck them on to the helmet.

I even put one on the back of the helmet.

After a few more applications, the green paint was becoming uniform in color.

Since I painted on the green without any sort of primer, the paint was not sticking very well.  I also became bothered by the seam from the 2 halves of the helmet.

So I decided to fill the seam and make the helmet one solid piece.  I removed the eyes and my green paint.  The image below shows some of the paint chipped off - which I thought looked really cool.  I may incorporate this into the final design.

While I did this I contemplated changing up the design a little. I googled what other people had done to stormtroopers and found a lot of cool designs.

So next I played with a few variants in photoshop.

After playing in Photoshop for quite a while, I became inspired by Commander Gree's helmet from Star Wars Episode III (seen below)...

...and I decided how I want my helmet to look like.

Now that I know how I want the helmet to look, I can move forward.  After the paint was stripped and cleaned, I added some wood filler to start filling in the seam.

In addition to the seam down the middle, I also filled in the rectangular areas on the front, back and bottom/sides of the helmet.

Once the filler dried I sanded it.

After some cleaning I took it to a parking lot where I applied it's first coat of primer.

The first coat was black primer.  The second coat was gray.

When the primer dried there were still some scratches from sanding and a crack at the seam.

After some sanding and cleaning, I applied some watered down wood filler to fix the crack and a few other spots.

When the filler dried I sanded and cleaned again.

Then I took it outside for some black primer.

Unfortunately that ugly crack formed again.

So more wood filler...

...followed by sanding and cleaning...

...followed by some spot putty...

...and then more sanding and cleaning.

Next I took it outside for some filler primer.

The seam can still be seen a little, but at this point I don't care anymore.  The helmet is going to look like it went through a battle, and I'm sure the crack will fit in.

I forgot to remove the 'ears' while priming, so I removed them and applied more primer.

When the primer dried, I gave the ears and the helmet a few coats of white paint.

And I left them outside to dry.

Once it dried I decided green would be the next color to paint on, so I added masking tape to the helmet.

I purposely didn't do a superb job masking the helmet since I wanted there to be some imperfections.

For some reason the green 'cracked' in certain parts of the paint job.  Normally this would upset me, but I like how it looks for this project.

When the green dried I removed the tape.  

There are several places where the green paint ran over on some white.  This is ok because I will later touch up these areas to look like chips and scratches.  I then put on the ears.

Next I masked off the front bottom of the helmet so I can spray on silver.

I'm not sure what exactly caused it, but like the green paint, the silver started getting messed up while drying.  But like before, I think this will just add to the helmet look.

Once the silver dried I then used white acrylic paint to 'fix up' the chipped and scratched look.

I also painted black to the 'mouth' and 'nose' areas.

And more white to create some worn stripes on the sides.

Black to the brow...

...and under the eyes and the ears.  I also used some silver paint to add some more wear and tear.

Next I lightly sponged on some black paint to create a little dirt and grime.

I decided to use use the older Jets logo on the helmet.  I printed out the logo and cut out the letters to use a template.

I taped on the template and used a thin black marker to trace the letters on to the helmet.

Then I painted in letters with white acrylic paint.

Then I used some more silver, black and white paint to add a little more scratches and wear until I was happy how it looked.

Next I took the helmet outside to some clear glossy enamel.

When the clear coat dried I glued on the eye lenses.

And I'm done!

I love how this helmet came out.  Thanks for reading!!


  1. As always - niiice! Nice to hear some of the history surrounding this impressive build, Timbo. And thanks for the impressive series of photos - instant tutorial.
    Best regards to you and yours.

  2. Thanks Phil! Always good hearing from you!