To Do List

Okay, Let's have a look...
Booster Jetpack?  Done!

Mando Helmet?  Done!
Overall with armor?  Almost done!

Boots?  Good question!!

Belt with leather pockets and blaster holster?  Under construction!

Blaster and Rifle?  Done!

Arm Booster steering/com unit?  Under construction!

Not long and I can continue on my '67 VW Beetle...

Mando Helmet and Greeblies

After a busy Saturday i am about to have finished the helmet and the greeblies except the tinted visor.
Here are some pics;

i made a silicone mold to get the r2d2 coin slots in resin. they will be applied to the rear of the helmet.

in the end it looked like this:

The (almost finished) helmet; the green has been applied too. i had to mask it with tape and added then again some toothpaste:

 i washed off the toothpaste and there it is:

Now on to the visor!
Therefore I visited my brother-in-law; he had some Plexiglass in 2 mm thickness for me.

Just some heating and cutting to get it bended to fit the helmet shape.

Update Mando Helmet

 Yesterday I found some time to do the last bondo works. next is the first layer of grey primer.

Well, the Mando helmet has now two layers of grey Primer on it.

 one in between step hadn´t been photographed; the base coat with silver metallic.

Now on to the greeblies!
Again some styrene sheets in 4 mm thickness and Ali parts will help me to get this quickly done too!!
Here you can see the first greeblie part hold to the helmet:

made out of styrene and aluminum.
and here is a shot of the already red painted helmet (with toothpaste under it for the used and scratchy look)

Mando Booster Jetpack

i could continue with the booster jetpack too!!

this morning i went to home depot and bought some new colour for the jetpack and the helmet!

silver metallic and red. so the work can go on...

here the jetpack already painted with a first layer of silver as a "base color" to get this metal look:

of course there will be more work on it! one or two more coats of silver have to be painted on the jetpack, then i can begin with the wheathering and the red paint. of course the ali greeblies may not miss this kit! parts of my r2d2 will find their way to it!!

the diet ali ankle details will be mounted here:

more pics tomorrow, when the wheathering will be done! now it´s drying time for the paint!!

Mando Helmet Work II

I was able to take care of the Mando Helmet yesterday.
All holes were filled, the front left side has its glued in parts too and everything is sanded and got a fine coat of bondo to eliminate surface imperfections.

 note; the front sides look different. the right side hasn´t yet been sanded but will have soon the same shape as the left side!

Mando Helmet work

next on the agenda is the mando helmet. i had begun with it last year, but due to some other projects and a lot of work in my enterprise couldn´t finish it right in time.

so this weekend i could continue on it!
some parts were cut out of 2 mm styrene sheets, to fill all the holes on the original mountainbike helmet, then glued in.

 from the inside i gave it some more strength; a layer of fiberglass and some resin with hardener and i am on a good way to resist cracks in glued areas!

Outer Ali Ankles

the second set of ankles had been made by myself out of aluminum.
here you can see ankle one already welded, ankle two in parts (not complete), already bended:

now the first ali ankle has it´s own bearing and tubing pressed in:

as you can see it has some light imperfections; these will be of course eliminated!

Ali Greeblies time

after having welded all of the second leg sheets, grinding was quickly done!
next step was to see, if all greeblies will fit the way they have to...

let´s have a look...

yess!! they do! under shoulder details aren´t on the pic, i couldn´t find them, when i made the pic! so holes have to be drilled there to get´em fixed!

next are the ankles. i made a set in steel and another in ali. but i haven´t made my decision which parts to use on my r2 unit... anyway, if someone is in need, maybe i can help...

Steel leg work

some more progress on the second steel leg!

here are the pics:

outer shell parts tack welded together. tubing for leg/ankle lock welded in.

bended sheets for under shoulder details on their destinated place, but not yet welded in.

everything inside is welded in now. outer sheet is welded too now.

now some more grinding and maybe rewelding and grinding to get a perfect leg.

and of course not to forget adding the small gap on the lower leg area to match the booster covers gap.

some minutes of welding and grinding later...then test fitting the ali horseshoe...

looks pretty good!! yeah!!!