Thank you both very much for your laud.
I would like to thank on this point to my buddys which helped me lot with laser cutting parts, some milling and searching parts.
Without those, such a project would be impossible to manage for me.I can't do all those parts alone.
So i'm very happy to have such good mates whom I can rely.

Thank you all!!

@ blip.

Wow, seems you have a lot of work done on your mask.
But it looks good and your upper mask fit's very well to the chinpart.Would say fit's better than mine.
Guess the base for your mask was also a Masterreplicas copy.

Let me know if you need any parts, have some left.
Also made from each part a drawing( interior of the chinpart and neckseal) if you need something on that point, simply ask me.

That's very kind of you Turrican - at the moment my reveal is a bit of a hodge-podge: Upper mask outside has forehead vents repositioned like OT vents and inside is PT (with the exception of the inside eye area which I free-styled, something about the 'frames' just doesn't feel right) and the rear neck I wanted smooth similar to Muir's original sculpt so I had to split the existing piece and re-form it and the lower jaw is OT inside.
That said the interior so far of upper and lower mask is largely magnetic/modular so I can swap out with improved pieces over time and having seen your jaw I'm tempted at some point to make alternate pieces or just do a new jaw - you've done a great job and nicely documented so it takes some of the pain away of trying to figure it out myself :D

And yes it is an MR 'copy' - though personally I believe it more likely they were seconds sold unofficially. I see no reason why someone re-casting an MR would go through the hassle of using a two-part mold on the helmet so it's smooth on the inside and also only offer black gloss painted not raw (which I inquired about) for such a ridiculously low price.

re: the upper and lower mask fit, I went insane trying to get them as flush as possible when together, part of my choice in the PT Vader helm was it's symmetry which as well as looking less funky in reveal mode when scrutinised also might prove easier to work with. Pre final paint stage the fit was spot on, I even went as far as grinding off and rebuilding both upper and lower parts *again* when I couldn't stop seeing the most microscopic of discrepencies which I couldn't work out how had happened. That said, now the final paint coat is on again it's thrown it out of whack again and I really can't bring myself to deal with it, it starts to get like chinese water torture and at the end of the day they won't be displayed as one piece.

Have you thought how you're going to display yours when finished? custom case? Anakin head?

That sounds realy interesting, what you have done to your mask.
Nice idea to fastening the parts with magnetics.
I for myself go for the sceen used . Hotglue...and well....the force.lol.

If i understand correct, you made a hybrid between the PT and OT mask?
Fell free to send me some pic's

Cause of the display , i plan to show it as it was on the exhibit.
Displaced, one upon the other in a class case with some nice led's.
Also thought on some light up from inside the mask ( on the eyes ).
But till i struggle my mind with this things, i have to complete this monster build.

well this is it's current state, I'll try to get a thread going soon and then you can get a kick out of the insanity of it :

I have most of the interior gubbins at hand to assemble (lucked out on the forehead vents on ebay when I bought a complete photomultiplier tube for £5 - not strictly accurate with regard to the rear circular cut-out but the seller turned out to live a couple of miles away and dropped it off free of charge)

Definitely think you should go with lighting the inner eyes - I've toyed with the idea myself - it would just make the interior really pop. I was thinking of checking out some of the RPF's (many!) iron man helmet build threads to see if there were any tips there that might be transferable.

Your display idea sounds spot on, tiered is the way to go - at the moment I've just stashed mine in an Ikea detolf cabinet - but as one side faces the wall then the mask inside (when it's finished) will obviously be hidden, so will need to think more on it. And I also like the idea of maybe replicating the mechanical 'claw' from ESB to hold the top helmet.

Keep up the excellent work Turrican.

im working on this myself looking for a nice base helmet.

for the lights in the eyes i have an idea but still in the works on these

Some new's.

Clamps for the neckseal are finished.

And also my new resin rotocast cable conduit's.



Just need to prime the cabel conduit with a few coats, that they get a little bit softer in details.

A Big "Thank you" goes to Justin( Justian) . Thank's buddy for your great help on these!

Today i made the flat ribbon cable.

Comparsion:

Replica webbing cable ribbon.
A lot of research has paid off

Ok here we go in the last hot phase of the build.
The ventparts.
After a lot of time in research, i couldn't find what was used neither what it nearly could be.
So i decide to build again some parts from scratch.
All i can say is, that to make those parts is a real pain in the ass.

Here's the outcome from 8 hours work.
From some junkparts,


to this:



Look how tiny those pieces are.



But as you can see here, they have the correct scale.

Some progres.

Made the tiny connectors on the sides.
Next is to made the wire connector plugs.





Testmount.

This is coming along rather nicely.

Yeah i also think so.
Thank's

Finished the small tiny connectors.
They only have 2mm in diameter. the small aluwire you see on this pic has 1,5mm.
I think after the clean up i can call them finished.

All parts come together now slowly if all will fit nice i can begin with the final clean up of the chinpart itself and the painting of the single parts.
One year in progress and finaly now close to finish, i'm realy happy with the result so far.

Cableconduit primed and bend in postion.
They are made out of rotocast resin.
I made a bolt-mechanism to mount them on the chinpart.I did the same with the finished vent's on the triangle part.
Also made the screwbase for the triangle.

Got my laser cut clamps and they fit perfect.
Not much now , just 4 small parts

Some pic's:

Looks great, and a fun build.

Thank's Ossi.
Fun yeah, but also a real pain, as while making those wires.



A real pain for my fingers.