I think Mac is right. The right size mesh for the mouth is going to depend on the make of the helmet. Given that, then how many grill openings (the diamonds) should go across the larger part of the mouth opening for the larger sized mesh? How many down? What about the inner mesh?

I have several size to choose from but cannot find a really good reference photo anywhere for this.

Wow, nothing on this? Ok, I will try to work off the few clear photos that I have to get some dimensions.

Honestly, I read your questions... but simply couldn't remember if the ESB mesh were the same as the ANH or if it was wider spaced...

The ESB Mesh was a wider mesh ... go ask KURTYBOY on the RPF for it,
he has both the Accurate ANH and ESB mesh for sale ...

Cheers,

Jesper

Oh crap... should have asked him for ESB as well... but hey... didn't know I was gonna change my helmet into an ESB back then... so I'm kinda excused.

But cool.

Cool, thx gents!

Does anybody know if KURTYBOY is still selling the accurate ESB mesh?

No ESB last I checked. Only ANH left.

Dang it!

Does anyone know of anywhere else I could get some accurate ESB mesh?

I have a piece I got from kurtyboy a couple of years ago, I found the exact same mesh recently in a builder's merchant's, you might try places like that if regular home improvement stores don't stock it.

You want steel mesh by the way (probably not galvanised) the original mesh on at least one Vader helmet shows signs of rust which I think rules out aluminium (though someone with more knowledge of metals can correct me on that if I'm wrong).


Jeremy

I picked up one of those Fram air filters today to use the mesh. It has the right look however I think it is too small to be ESB accurate. The high definition screen shots seems to shows about 6 mesh holes up at the highest and 4 mesh holes across at the widest (I'm referring to the lower grill)

What color was the mesh? It seems to be painted the same grey that's on the faceplate. Or is it just a dull silver? I'm sure this has already been discussed at length so I apologize if I'm bringing up an old topic.

It's unpainted steel I believe which looks a shade duller than bare aluminium. The metal has a very similar colour to gunmetal or steel-grey paint.


Jeremy

I finally went out and got a large truck filter and the mesh on that was just the right size for the chin vent.

Though after looking at some reference shots from ESB it seems to me that the mesh in the mouth vent is different from the mesh in the chin vent. Same height but about double the width. I dropped by my local home improvement store to see what they had available but I couldn’t seem to find any mesh anywhere. What section of the store do you usually find it?

Also a second question, what kind of mesh was used behind the larger mesh on the screen helmets?

What truck filter did you get? and where did you find it? I have been looking for better grills. Since I have the grill out of the mask now this would be a good time.

It's not the best, but WalMart sells filters by FRAM. You could probably blacken it as desired. If you get creative, you could also cut strips so that the diamonds line up with the holes.