Storm Trooper Episode VII Foam build (Pic Heavy)

Status
Not open for further replies.

Ashuraa

Research Team Lead
Member DIN
S015
Well, I took on my first commission, and it was for a storm trooper helmet. I have never made a storm trooper helmet before, and never one in foam. Needless to say I took a great big step of faith to go forward with it.
I used rundown 's Pepakura file and modified it to use with foam.
Here are several various pictures of it in various stages of progress.

First several are after I had gotten the base form of the helmet done, and the lower jaw. I used 5/16th inch foam for the whole helmet. I also used contact cement to glue it all together.

IMG_20150610_125525838_zpscotnelza.jpg

IMG_20150610_125535744_zpsk3f9m2tx.jpg

IMG_20150610_125545127_zpsjmppzvaj.jpg


IMG_20150610_125558852_zps4kav9awb.jpg

Here I had added the mask part of the helmet. I also had found a small probiotics pill bottle that fit perfectly for the nozzle type attachment in the front corner of the helmet.


IMG_20150615_202951100_zps2pqs20pm.jpg

IMG_20150615_202959517_zpsu3ewd37j.jpg

IMG_20150615_203010535_zpsrwtg5a1w.jpg


Next i sanded down all the seam lines, with first 80 grit sandpaper, then 120, and finally with 220. After that I used a sand-able, paint-able, white silicone compound to smooth out what ever gaps I might have in the seams, along with any surface flaws left in the foam. I also added all my detail foam pieces, and added the final cut ins along the cheek guards. I also placed in some temporary stays of Popsicle sticks to keep the visor opening spaced propely.


IMG_20150624_174114220_zpsdyq2b5or.jpg

IMG_20150624_174122745_zpsc5mvhc1o.jpg

IMG_20150624_174127226_HDR_zpsvy31xjw3.jpg

IMG_20150624_174137605_zps5q6q9pz7.jpg

IMG_20150624_174146974_zpsxrafcyrx.jpg

IMG_20150624_174158110_zps6mkuqzrd.jpg

Here you can see where I cut down and sanded down the bottle to sit flush with the rest of the foam.

IMG_20150624_175140153_zpstx9pdtdf.jpg

After all of this work, I then added 3 super thin coats of Pour-On Lite resin over the whole helmet, and sanded well between coats to get an ultra smooth slightly hardened exterior. After the third coat it was so smooth that even when it was dry touching it made you think it was wet. At that point I then used a high gloss black spray paint over all the areas that where to be black. I then tapped those areas off after they were dry. Then 3 coats of high gloss white paint went onto the rest of the helmet.

Finally I made my visor with my pattern. i made it so that the visor was a little larger then the area it was supposed to be in. I coated the inside of it with 5% LVT window tint. After taking out the temporary stays, I then put in the visor and glued it into place.

Here is the finished product, and the happy owner.

IMG_20150710_104241858_HDR_zpsrlyvhj3r.jpg

IMG_20150710_104254762_HDR_zps6hktp2p7.jpg

IMG_20150710_104305858_HDR_zpsibouujcx.jpg

IMG_20150710_104319836_zps9wqp6qfk.jpg

IMG_20150710_104330197_HDR_zps97mrqey5.jpg

IMG_20150710_104340965_HDR_zpsfxdcyc5c.jpg

IMG_20150710_104351664_HDR_zpsr2l4duno.jpg

IMG_20150710_104456144_zpsiul3xyk5.jpg

IMG_20150710_104512246_zpsl24wagdu.jpg

IMG_20150712_145552139_zpsxpyysd6y.jpg

IMG_20150712_145602742_zpsboh5losp.jpg

Oh.. and looking out to the world through the visor

IMG_20150710_104401704_zpsdydyykl4.jpg

IMG_20150710_104415404_zpsn5lferzt.jpg
 

Attachments

  • IMG_20150610_125525838_zpscotnelza.jpg
    IMG_20150610_125525838_zpscotnelza.jpg
    185.6 KB · Views: 208
  • IMG_20150610_125535744_zpsk3f9m2tx.jpg
    IMG_20150610_125535744_zpsk3f9m2tx.jpg
    175.1 KB · Views: 211
  • IMG_20150610_125545127_zpsjmppzvaj.jpg
    IMG_20150610_125545127_zpsjmppzvaj.jpg
    181 KB · Views: 197
  • IMG_20150610_125558852_zps4kav9awb.jpg
    IMG_20150610_125558852_zps4kav9awb.jpg
    199.7 KB · Views: 211
  • IMG_20150615_202951100_zps2pqs20pm.jpg
    IMG_20150615_202951100_zps2pqs20pm.jpg
    137.6 KB · Views: 205
  • IMG_20150615_202959517_zpsu3ewd37j.jpg
    IMG_20150615_202959517_zpsu3ewd37j.jpg
    136.7 KB · Views: 213
  • IMG_20150615_203010535_zpsrwtg5a1w.jpg
    IMG_20150615_203010535_zpsrwtg5a1w.jpg
    141 KB · Views: 214
  • IMG_20150624_174114220_zpsdyq2b5or.jpg
    IMG_20150624_174114220_zpsdyq2b5or.jpg
    207.7 KB · Views: 207
  • IMG_20150624_174122745_zpsc5mvhc1o.jpg
    IMG_20150624_174122745_zpsc5mvhc1o.jpg
    234.1 KB · Views: 209
  • IMG_20150624_174127226_HDR_zpsvy31xjw3.jpg
    IMG_20150624_174127226_HDR_zpsvy31xjw3.jpg
    263.9 KB · Views: 216
  • IMG_20150624_174137605_zps5q6q9pz7.jpg
    IMG_20150624_174137605_zps5q6q9pz7.jpg
    236.3 KB · Views: 208
  • IMG_20150624_174146974_zpsxrafcyrx.jpg
    IMG_20150624_174146974_zpsxrafcyrx.jpg
    251.7 KB · Views: 204
  • IMG_20150624_174158110_zps6mkuqzrd.jpg
    IMG_20150624_174158110_zps6mkuqzrd.jpg
    255.3 KB · Views: 230
  • IMG_20150624_175140153_zpstx9pdtdf.jpg
    IMG_20150624_175140153_zpstx9pdtdf.jpg
    200.3 KB · Views: 202
  • IMG_20150710_104241858_HDR_zpsrlyvhj3r.jpg
    IMG_20150710_104241858_HDR_zpsrlyvhj3r.jpg
    170.4 KB · Views: 220
  • IMG_20150710_104254762_HDR_zps6hktp2p7.jpg
    IMG_20150710_104254762_HDR_zps6hktp2p7.jpg
    182.8 KB · Views: 206
  • IMG_20150710_104305858_HDR_zpsibouujcx.jpg
    IMG_20150710_104305858_HDR_zpsibouujcx.jpg
    200.7 KB · Views: 211
  • IMG_20150710_104319836_zps9wqp6qfk.jpg
    IMG_20150710_104319836_zps9wqp6qfk.jpg
    147.3 KB · Views: 216
  • IMG_20150710_104330197_HDR_zps97mrqey5.jpg
    IMG_20150710_104330197_HDR_zps97mrqey5.jpg
    168 KB · Views: 205
  • IMG_20150710_104340965_HDR_zpsfxdcyc5c.jpg
    IMG_20150710_104340965_HDR_zpsfxdcyc5c.jpg
    171.6 KB · Views: 201
  • IMG_20150710_104351664_HDR_zpsr2l4duno.jpg
    IMG_20150710_104351664_HDR_zpsr2l4duno.jpg
    170.2 KB · Views: 215
  • IMG_20150710_104456144_zpsiul3xyk5.jpg
    IMG_20150710_104456144_zpsiul3xyk5.jpg
    107.3 KB · Views: 227
  • IMG_20150710_104512246_zpsl24wagdu.jpg
    IMG_20150710_104512246_zpsl24wagdu.jpg
    114.7 KB · Views: 209
  • IMG_20150712_145552139_zpsxpyysd6y.jpg
    IMG_20150712_145552139_zpsxpyysd6y.jpg
    126.4 KB · Views: 217
  • IMG_20150712_145602742_zpsboh5losp.jpg
    IMG_20150712_145602742_zpsboh5losp.jpg
    124.8 KB · Views: 210
  • IMG_20150710_104401704_zpsdydyykl4.jpg
    IMG_20150710_104401704_zpsdydyykl4.jpg
    106.8 KB · Views: 199
  • IMG_20150710_104415404_zpsn5lferzt.jpg
    IMG_20150710_104415404_zpsn5lferzt.jpg
    88.7 KB · Views: 196
Last edited by a moderator:
Ashuraa
Great looking foam build! Any chance you might share what base material you used for the eyes?
 
Last edited by a moderator:
What I used was plexiglass that I cut to size then curved with a heart gun. I also used 5% viable light transfer auto window tint. I applied the tint before I installed the plexiglass. I used high temp hot glue to install the visor
 
Hey,
I'd really be glad if you could post the foam template, as I really need it urgently for a convention coming soon and I have very limited time to learn Pepakura.
This is my first post here, I do have professional 3D design skills that would benifit this community :)
Also apologies if bumping such relatively old threads is prohibited.
 
Last edited by a moderator:
Status
Not open for further replies.
Back
Top