propsmith wrote:
I think the whole thing would take a HUGE step forward when one of the two primary theories become proven fact:
Theory 1: there is ONE mold made back in the day (technically two - UK and US mold) from THE ANH helmet. No new molds for ESB and ROTJ - they came just as ANH out of the mold and were then modified to the desired look.
Theory 2: multiple molds were made - definately for ESB (ROTJ unsure).
I have no clue whatsoever since I don't have the sources other members here have.
I think none of the members here have ever seen a UK mold in person, me included. I tend to believe in theory 2. One master UK mold was produced from the screen used ANH faceplate. Castings were taken from that mold for production, tests, and as souvenirs. At least one of these castings has been altered (for ESB production?) - the casting was molded and this second gen. mold produced the TM (deeper eye sockets, deeper teeth on "original" TM casting). Perhaps another casting from the UK master mold has been cleaned further (removal of cast tabs etc.) and was molded again to produce another second gen mold for ROTJ production. Perhaps the master UK mold got detroyed at one point during production, and a new mold had to be produced from a first gen casting. I worked in the movie business for more than 25 years, and have witnessed similar things happening on other films.
Based on the sheer size of the faceplate casting, the TD could be a pull from the master UK mold (although the tusks were cut short on the casting). Dunno about the size of the GS casting (yet), one would assume that it is from the ROTJ era based on the dome. I have recently learned that ROTJ style Vader domes were already existing in around 1978 (more about that perhaps later in another thread), so it might be possible that the GS is a casting of the master UK mold.