Hello. I have been working on an ROTJ Vader build for a while, and it occurred to me that a semi-stunt helmet with transparent cheeks would help me a lot to improve visibility for my costume. I'm not going for extreme accuracy on this piece, just get it close enough as I can to what was on screen.

I got this awesome GH cast by Tony Le.




I trimmed it and reshaped the dome to a much closer look to the movie.



Using the mask as base, I heat-molded some Polycarbonate sheets for the new transparent cheeks.



Then came the scary part... I cut off the cheeks !



I used epoxy clay to install the PC cheeks, and integrate them as much as possible.



After some more adjustments and refinement, I applied the primer and sent it off to have the dome fully painted black.
The mask will only receive a first pass of dark-gray paint, I will then paint all the black details on the mask and send it back to get the final clear-coat.
I will update this thread as soon as the helmet comes back and I can continue. I'm very happy this project is coming along nicely.
Cheers!

Looks great. How did you fix the dome flare? It looks really good now.

Thanks, man! I used a heat gun and gloves to reshape it with my hands. I then held the position until the dome hardened, and used a leather belt while it cured for a couple of hours.

I basically squeezed the sides in, until they where about 28 cm apart. I also kept the flare as straight as I could. The trickiest parte was to avoid the back edge of the dome flare from looking skewed or wonky.
It took me a few tries to get a good shape! But thankfully, it worked great on the last attempt.

One other thing that helped get a good look was that I adjusted the dome mount height and position a bit.



Here are some more images of the final dome shape.

Perfect. And I never realized the GH RotJ dome had so many bumps on the surface. I thought it had been smoothed out more. Pretty cool.

And to take on the stunt helmet mod is not something I would dare, so well done on that too.

Looking awesome cant wait to see it all done.

Looking great my friend!

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New update! I sent the GH to a professional auto painter.
The dome is finished, I will spray paint the remaining black areas on the mask and then send it back for a final transparent coat.

And, I unmasked the cheeks! Even if they are not 100% seamless, they are looking quite good, IMO.

GREAT JOB!


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Thank you, man! Your gorgeous ANH helmet is the main inspiration for this project

What a nice paint job. Like that it wasn't made super smooth and shiny, but has some orange peel to the surface, which is accurate to the originals. Well done.

Thank you! At first, the painter was worried about the orange peel. He could not understand why I asked him to keep it, lol.

Yeah, just tell him he did a great job replicating the original job. He's now transcended from painter to also include replicator. :)

Nah... probably don't tell him that last part... that seems too nerdy.

Almost done.

A helmet to be proud of. :)

Looks good. Well done.