Hello forum members,

Around 10 yrs. ago I acquired a DP Dlx. This was long before I discovered the forums and at the time I knew nothing about Vader helmets. I got the helmet at a relatively low price so I decided to experiment with it. At the time I was able to sharpen some of the soft/warped details but I went a little nuts customizing the neck and ring mount. As of a couple months ago this is what my DP looked like:


I found this forum several months ago and it has given me motivation to work on my old DP again. The pics below show examples of how I did my work. I was going for ESB. Basically apply autobody filler/bondo and sand with sandpaper until I get the shape I want then repeat over and over. I did this process with the eyes, nose area, cheeks, teeth, and lower vent:


Here is my rough draft in primer:


And after a few minor adjustments the final results in paint:


A few outside pics:


Its not perfect and its idealized to suit my taste, but I wanted to contribute something to the forum since I've been enjoying looking at all of the other members work and helmets.

That's looking very nice. Well done!

Great result, looks spot on

Thanks guys. I lost count of the days and hours I worked on this project. I sincerely appreciate your positive feedback.

Excellent work

Apart from modifying the center strip did you do anything else to the dome? It looks like you might have extended the "skirt" of the dome.

Wow! That turned out great.

Job well done sir!

I actually over extended the dome skirt and then trimmed it down until it looked the way I wanted. It's only extended around 1/8" inch or so. The reason the skirt looks longer is because of the height and tilt of the dome position. If I was to mount the dome higher and tilt it forward a bit it would look more like the typical DP dlx. Camera angle is also a factor. I also heated the dome and manipulated the shape of the skirt just a touch. I put a skim coat of body filler/bondo over the rest of the dome and shaped it with sandpaper.

Screen shot comparison for fun:



Not perfect, but a good replica for now. Getting the dome to look right is a real challenge.

I'm no Vader expert, but this definitely seems to be understatement.
This helmet looks awesome, very well done and already highly accurate

Although it is missing all of the wonderful lumps and bumps, it still is an impressive piece of work. Did you paint this yourself?

Thanks again for the positive comments fellas.



Thank you Darth Stone for the compliment. I feel the lumps and bumps should stay with the truly authentic cast where they belong. Yes, I did the paint work at my shop. I use the PPG line of automotive paint. I'm sure you are familiar with PPG given your background in the auto-repair industry. I used Toyota paint code 1E3 Phantom Grey for the gunmetal.

I don't have access to color code books any longer. But I'm sure the Toyota color is quite close. I wish I had a color code for mine. The paint rep and I spent an afternoon some years ago coming up with a custom formula and we just kinda gave it our own name. If I pop in to get more color when my normal guy isn't there at the paint store it is always a bit of fun explaining what, "Darth Vader Gray #17" is.

Thats funny. Gotta remember to record those paint tint mixing ratios next time you make your custom color. I know you don't need it, but I am still in the industry so if you ever needed info on any of the new products available I would certainly help you any way I could. That goes for every member here as well.

Thanks for the offer.

I do have the mixing formula just about committed to memory. And with having a credit account with them I get all sorts of junk mail just about every quarter telling me of new products and shop equipment. Much of it I can only still just dream of owning one day. A decent gun washer springs to mind at the moment.

The act of painting, and the materials used are both separate topics and often are one and the same. Ambient air temperatures, pressures, moisture content, and even just the techniques of the painter are all just as important as which reducer or other products used. It really is of no wounder that in an autobody shop paint and body are separated into different departments and often even have different mangers.

Painting something like a Vader helmet is allot like painting a custom motorcycle. Very detailed work that you must put on stands to shoot and hope that the air pressure from your gun doesn't send them to the floor. Anybody who can do this with results such that you have achieved and not be arrogant about it will always have my respect.

I have no problem saying that I have admired your fantastic work as well Darth Stone. Your work bench has some of the best products in the hobby. And from what I can tell you've conducted yourself with class and maturity within these forums. The respect is mutual. Best of luck with all of your projects.