Rebel Soldier Costume Helmet
rogue one rebel solider
HOW IT WAS MADE:
These days, my custom work primarily revolves around an intial 3D print, but I wanted to go old school on this rebel solider helmet - ALL SCRATCH-BUILT! I started with the same M1 hemlet I used for the COLONIAL MARINE project. I thermal formed 5 sheets of 1/8" styrene over the top of this hemlet to give me a VERY THICK shell.
I vacuformed one extra pattern off the top to give me a pattern to hand-draw the artwork template.
The finished tracing pattern:
You can see how crazy thick the final result is! I removed the two INNERMOST shells to allow ample room for the fabric cover which will be added later.
The innermost shell was removed and the outer shells trimmed with the rear detail inset. The shells were then reassembled permanently.
The rear panel was designed in 3D CAD and laser cut to fit the inset.
THE DETAIL PARTS:
The flashlight piece is a rod that is finely grooved. I made it using laser cut styrene and acrylic, stacked on one other to achieve the desired detail. The deathstick pack was made using carving foam.
I designed the camera box in 2d and laser cut the sides and body. The parts were assembled and detailed with tubes.
The work on the helmet shell continued with carving the inset holes using laser cut stamps and good old elbow grease (dremel, bondo, files, and sandpaper)
The parts before a few more days of fine cleanup work and prep for molding: