A few months ago I bought this clone mask figuring that I would attempt to make a standard clone helmet out of it.
I eventually decided to simply fix up my clone helmet that I already had. The mask hung around for a while until one day while shopping at lowes, I bought this hard helmet.
I decided it would be fun to make a helmet using both pieces.
I feel I should mention that this is not a helmet seen anywhere else. I'm not trying to base this off of anything I've already seen. I simply feel like just having fun with it.
To start, I removed the visor to the mask.
Next I cut out the dome to the clone mask.
I sanded the edges and then taped the mask to the back rim of the hard hat. The tape held it in place and I applied some epoxy to the insides to bind the 2 pieces together.
Next I cut 2 strips of styrene which will make up the bottom and back support for the helmet.
I glued the strips together.
And then connected them to the bottom of the face mask.
I then cut some thinner styrene to make up the back of the helmet.
And glued that to complete the back of the helmet.
Below are 3 clone helmets I am working on side by side.
Clone Utility helmet, The Clone Wars Clone Helmet and Ep. II - Attack of the Clones helmet.
Before I can do anything more to the helmet I needed to seriously strengthen and support the joints between all pieces. So I took out my fiberglass and started cutting strips of it to line the inside of the helmet.
I applied small amounts of hot glue to keep the fiberglass in place.
Then I applied the resin and let it cure.
Once the F&R dried, I traced some shapes on thick crafting foam.
I then cut them out.
...and started gluing them onto the helmet to form the 'ear' area, and wrap around the back of the helmet.
Using more foam, I created the bottom/back of the helmet.
Then I used some various thicknesses of foam to add other elements to the helmet.
I glued on some coin capsules to the ear areas.
So far the helmet is looking good to me.
There's a lot of static coming off the plastic hard hat, so I cleaned up the helmet and then gave it a first coat of filler primer.
Here in NY we are having some weird weather. It was sunny when I started painting this helmet. Literally 2 minutes later it began to rain. Those drops you might see on the helmet are raindrops - but any imperfections the rain might cause will easily be fixed once the primer dries.
When it did dry I added some wood filler to fix a few gaps.
When it dried I sanded the whole helmet and fixed those slight imperfections from the rain.
Next I started to add on some more details. For the 3M logo which was on the brim of the helmet, I glued on a deodorant cap - which fit the 3M logo perfectly.
I had also recently bought 2 bamboo plants, and I kept the tubes they came in.
I glued the tubes to the sides of the helmet. The ends are hollow, but I will eventually put some kind of flexible tubing coming out of each end.
Thin strips of foam were also added...
...as well as a nerf foam disc and a coin capsule...
....and also the dial of some electronics (perhaps it was part of a toaster - I honestly don't remember where I found it).
Then it was time to go outside and paint on another layer of primer.
When the first coat dried, I applied a second.
The next day I did some minor cleaning of the helmet and then gave it a few coats of white spray paint.
I noticed a few imperfections such as a big crack on the side and a bump on the dome (which I forgot to sand off). I decided to leave these be, and make it look like some wear-and-tear occurred. After all, you never ever see a perfectly clean clone helmet.
Below the clone utility helmet and the AOTC Clone helmet dry outside.
When the paint dried I decided this helmet should have some yellow coloring for caution/utility. So I added yellow elements with some acrylic paint.
Then I started adding some gray to the nose, mouth and back areas.
Next I used some black and gray paint to add some wear and tear.
I also used some red to add some symbols here and there.
Then it's time to go outside again for some glossy clear enamel.
When the clear coat dried I reattached the visor.
And then I used a piece of flex tubing to connect the 2 open ends of the bamboo tubes.
And I'm done!!!
This was a very fun project to work on, and believe it or not it only took about 5 days to make.
Thanks for reading!!!