Making a Mandalorian - Episode 6 - Helmet Casting and Painting 

It’s not really until you start making armor yourself, do you realize how much work goes into it. Huge respect

Would you ever consider making a Death Trooper helmet/armor

That looks incredible! Don’t hate yourself for this, it is the best Mando helmet I’ve ever seen!

Don't be hard on yourself over some problems you encountered. That's how you get better at your craft. And this looks awesome.

WOW! Now this is one badass video! I've been wanting to try helmet moldmaking for a while now.

Hey man, this is amazing. You are just incredible at what you do. The helmet is easily one of the best I have seen, which is the same with all of your helmets. It is also amazing to see how many people you have inspired, me included, to get a 3D printer and try our own project. I have bought the arc trooper helmet files from your shop and am going to try make that when my printer arrives. Thanks.

When doing keys, I wouldn't recommend doing them inverted like that as it causes really prominent undercuts. When you "lock" those into the resin / fibreglass it can cause stress on those points each time you release it from the mold. You also run the risk of locking the silicone inside the resin shell causing them to tear off if the silicone used is harder. One thing that works great are ice cube trays. Then, place the keys with the bigger side down, this will create little tapered rectangles that work really well.

Congrats on the great project. I know you were down on yourself for not hitting your level of quality by Oct 31, but this is still many times better than most costumes I have seen made on this site.

I love watching these videos they are just so well done and unlike many people on RU-vid it actually has original content and I’ve looked for other people on RU-vid that make the type of things as this channel does and I can’t find any. I just really enjoy the content and generally everything about the channel

Made my own mando helmet following your videos as inspiration. You’re doing just fine man

once again a top performance in art that you did there

I finished my very first mandalorian helmet today using your files. Took me about a month for the whole proces. It turned out so good with the graphite finish, thanks man!!

I'm so happy you molded this helmet! It saves so much time!

That's pretty good, especially for a beginner in this field! Nicely done!

Hope your mental health is going strong! Loving your videos

You were one of the people who got me into 3D printing, seeing how awesome your projects were. I'm now making my own helmets and props all thanks to you!! When I look around my house I see all the things I made with my printer, they would not be there without you. Honestly, keep up the great work, we all have ups and downs and you can know that we'll all be here to support you whenever you need it. Like with all the other things you make, this project is look so good! Truly an inspiration mate :D

Looks great bro. Probably best mando helmet iv ever seen.

Im glad we were able to help, I had thought you would use the other helmet that you already had for the project though unless that was just meant to be a display piece.

This is the way ~ You did a Incredible Job! 🔥🔥 Its so informative and detailed, thank you for sharing your progress and passion!

Dude this is freaken FANTASTIC

Nice job keep up the great work.

i'm gonna give you a couple of tips, you don't need the silicone plugs stuck all over the outside of the mold, they are only used by people that don't know you don't need them. the silicone ain't gonna be flopping about inside the mother mold , that is why we use a mother mold. secondly try a multi tool for cutting out the visor, i almost use this tool now for everything, its quicker and most importantly produces MUCH less dust, nowhere near the amount seen in this video.

Wow, I thought making the 3D printed helmets was difficult, but this is way more of a challenge. Please give yourself a huge pat on the back for working so hard on it and don’t give up. It looks fantastic!

Try rubbing graphite powder on top of your paint job, or on top of just the primer or matte black. Works & looks amazing. Still dark, though.

Again, I’m really digging your work. You can get some thing that vibrates and attach it or strap it down to a table that you have your object on. The vibrations will help the bubbles lift to the surface

dude, you're a big part of the reason im buying a 3d printer, the creality cr-10 to be precise :) , ive been intrested in 3d printing for sometime now but it never seemed that accessable, it still blows my mind that for the price of one nice 3d printer, i can pretty much make anything i want. suits of armor that cost thousands in some cases can be made in a fraction of the cost. the quality of these helmets/armor sets is amazing, and if i can make anything half as good ,ill be stoked. keep making these amazing peices, and may the force be with you

Mad respect you can see how much work goes into this

Nice Video man, came out 6 secconds ago and i clicked on it so I cant say much about the video but im sure it's awesome im really looking forward to this project :D

Found this channel figuring out how to make the cape. I really enjoy this content, you’ve earned a subscriber! I can’t wait to see the final results.

It looks awesome! You should see my helmet haha. Finishing it up just now and while it doesn't look great I've learnt so much along the way of making my first helmet thanks to your amazing content!

Greetings from Germany, I'm stunned how much work you putt into this. Il hope you keep on doing this in future! good luck for new Projects!

Thanks man, been following your progress and been thinking of casting armor pieces myself, and such a helpful video. Big thanks man!

Have you thought about using a metallic powder actually brushed in the mold? or even cold casting by adding some aluminum or nickel powder to the mold and pulling out a cast in Onyx black resin? I bet it would look amazing!

Amazing job a little fix here and there and your armor will look great

Respect for the time crunch. Your a legend

I'm loving this series thank you so much!

You make such a Great Job. Keep it going 💪🏽

It’s looking super good

When you start a new cast do yourself a HUGE favor. Put in Aluminum powder in the epoxy. When it comes out of the mold its going to look grey and dull. But, if you use scotch bright/ steel wool at different grits. IE, as you would if you were sanding you can get it to a mirror finish. Might want to give this a shot

Wow!!!! This is amazing. Can't wait to see it finished!!! I bet it will look awesome!!

I made a Clu (from tron: legacy) helmet out of hot glue, cardboard, and a tinted face shield with good results! This inspires me to make some ARC trooper armor next. You don't need a 3d printer to have fun making helmets!

That helmet looks amazing 👍

Keep it up! I love watching your videos and I am always inspired by how good yours come out! It keeps me motivated to keep improving my methods and learning new skills.

I’m definitely thinking of going this mold casting route cause I want the armor to be hefty but not heavy.

Nice video. Love your work

Nice job man, I really enjoy your vids! I would print myself some armor but my 3d printer is small so it would take about a year lol

A 212th trooper helmet would be cool. And I kinda wanna get the DIY Commander Cody helmet parts when they’re in stock.

You rock. Your patience seems boundless with some stages in this 12min video having taken a week it's easy to underestimate all the work that goes into what you do. It looks good but don't let the best be the enemy of the good if you know what I mean :)

Arm hair wisdom.. super helpful! And the pain is real!!

This looks freaking great! Better than anything I've made! I look foreward to seeing more videos from you m8.

Loved this man! This is legendary!

Just a little advice, not sure if you need it, but if you feel like the helmet is too low to the shoulders, put some foam on the inside or wear something under the helmet it elevate it

Get your self a small compressor and a good spray gun, forget spray cans they just don't give you the right fan shape and consistency to get a smooth finish. I use the devilbiss FLG5 gun and you get perfect results every time.

Wow that looks great! I would love to see you do some more characters from The Mandalorian in the future. Maybe a Deathwatch mando from the flashbacks to tie back into the clone wars?

I would suggest instead of the filler primer try using what's called Adhesion Promoter. Its used in auto body and gives you the same properties as using primer but is more flexible.

You should wet sand the 2k clear coat, then apply another thin thin layer. Crazy orange peel on some spots and it would help the alumaluster shine better.

I've seen other people do matte color, and then 2-5 layers of clear coat on top, in order to have better control over the gloss effect.

Keep up the good work love you’re vids

Nice! It looks good!

love these videos! you are so good!

For my helmet I wasn't able to source a face shield for the T-visor so i decided to experiment with some stuff I had on hand. With some patience i was able to apply 5% tint to a piece of transparency paper and it wound up being flawless. Only thing is that it is very easy to get creases on it when trying to glue it in place.

Since you are priming/painting on plastic.... get a spray can of SEM adhesion promoter and spray that on the resin first. As for the allclad, or other "chrome" paint... use a detail air brush. Basically a miniature version of a car painting gun. This will give you a wider pattern instead of the circle shape from an airbrush. :)

Can’t rush perfection I’ve been having my own problems with my arc fives helmet which I commented on the last video about but I spent weeks trying to find the perfect blue for the helmet and eventually I had to stop and get something that was as close as I could get with the paints I had access to

Great work! Would you ever consider selling a resin cast of your clone helmets?

Alumaluster is tricky. Works best in an HVLP setup. With the fan almost closed and high air pressure. It’s really difficult to get the proper shine with an Airbrush.

Hi. I tested Alclad chrome and also Molotov chrome pens (opened up) to spray a nice chrome on mine. Came out very glossy though. After the clear went on it settled down. Just a thought.

Awesome job!! Have you thought about adding something to the inside midway through the curing time to add some rigidity to the cheeks?

Try spray polyester body filler using a gun with disposable cup. Sands way easier than that old lacquer spot filler. Can get at automotive paint supply. Great job. Respect on finding a good chrome alternative. Not easy!

Really good!

Thanks for passing on the knowledge!

looking awsome top quality !

you are so detailed, in a good way 😄

Might consider gloss black+ rub n buff+ gloss coat. It looks great that way.

Omg this is soo cool!!

Looks fantastic! However, if you're not happy with the results, keep on perfecting it and enjoy the journey!

Wow amazing. great job!👍🏻

Hey this is awesome I'm just wondering if you remember how much filment the print took?

I want to buy your parts and make a series of my own man. Been sending RS Prop masters for a Boba Fett ROTJ commision BUT DAMN... I want to give this a shot!

I purchased a resin cast helmet not to long ago and the thing that almost ruined my paintjob was not priming. I was so used to foam and 3d prints that the solid-ness overtook my common sense. It is so important

I like the "new" intro. New to me anyway 😂

I'M SO EXCITED

Thank you for showing the alumaluster going on. I want to use that but the price and not knowing how to use it is a big hurdle. Keep up the great work. As for a paint booth, check out "I like to make things". He has a great paint booth design. I made one so I can paint all winter long in snowy Iowa.

you should definitely use a wider nozzle on a big air brush to get even coverage, I'm talking like one that you hold with your whole hand that people who paint cars use.

nice paint job

Good job dude, your dedication to making this armor is pretty high right now and feeling let down because of the amount of work you have to do is understandable, I live with that to, we all know you're great at what you, do keep it up. P.S. do you sell 3D print files for basic blasters on your website?

That's awesome, but i wonder if you can see through that visor

Its great!

Would you consider giving away or doing a competition where we could win the failed casts of the helmet?

Love the vid, but why didn't you use your old mando helmet?

I noticed on one of your other helmet builds, I believe the 3-D printed, you made it a little more narrow to fit your head, elongated. The helmet that you put on the dummy... I noticed you also tried it on, was there some space on the sides or is it a fairly tight fit? I remember in your custom MANDO helm ( the blue/white one), you had made that one custom, to fit your head (Narrow/elongated)... are you going to make one like that for your suit? I made my helmet by hand using a children’s bicycle helmet (completely smooth top) And a Home Depot bucket, it turned out great. It would’ve been awesome if I would’ve recorded everything I did and it wasn’t even hard. I had looked at the technique ./RU-vid channel: The Bearded Mando used. I will film it from here on out in small bits and eventually post it.

"The mando is winking at you."😂😂😂😂😂😂

Looks great! Keep going!

Looks incredible! Is it possible raw casts of future helmets will be available in the online store?

Us:*sees bondo’ed up helmets in the background* Also us: REX HELMET!!!

Thanks!!, very useful!!

Would you say that having a respirator is Mandotory ? ;)

Craaap...my 3d printed one is coming in tomorrow from you. Well jokes on me I guess.

Casting definitely makes helmet making easier

Very cool video

Nice video ! I just didn't understand why you didn't use the printed helmet as well as you others tutorials.