1. Watch City Armory

TK Helmet Assembly

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  • Full Kit

    Full Kit

    This is what you'll be getting.

  • Cap & Back

    Cap & Back

  • Trim the excess flashing off the face

    Trim the excess flashing off the face

    When you get the kit, the face will have some excess plastic. Trim the line straight up and down.

  • Masking tape helps

    Masking tape helps

    It's easier to do if you mark off with some tape where your lines should be.

  • Test fit

    Test fit

    Yes, magnets are involved in every build I do. I use 5 pairs of rare earth magnets for my test fit: 2 on the center of the forehead, a pair each on the side traps, and a pair each at the tubes on the side.

  • Test fit, other side

    Test fit, other side

  • Stunt Brow

    Stunt Brow

    The stunt helmets had higher foreheads. Don't know what stunt helmet means? Go to http://www.starwarshelmets.com. Go on, I'll still be here when you are done!

  • Stunt, side

    Stunt, side

  • Tools for the face

    Tools for the face

    There are 2 Dremel bits I use: The sanding drum and that small cutting bit to the right of it. I have a corded and a cordless model. I use the cordless whenever possible, since it's easier to not deal with the power cord.

  • Closeup of the bits

    Closeup of the bits

  • Dremel Sanded

    Dremel Sanded

    Cleaned up with the dremel sanding drum

  • Lens, test fit

    Lens, test fit

    Holding the lens in place

  • Rough cut

    Rough cut

    This is how they look after the dremel.

  • Squared up with files

    Squared up with files

    I used a small square file to finish the job.

  • Face is ready!

    Face is ready!

  • Small screw hole

    Small screw hole

    I reassembled, checked for the last time, then drilled a small hole right near the tube.

  • Small screw

    Small screw

    Into that small hole goes a little #4 screw. This helps keep it from slipping around.

  • top edge

    top edge

    if you look at the helmet from the side, you'll see that the ear is spanning the overlap between front and back. To make it fit better, I sand out a little indent at the back of the ear. This lets it nestle into the indent better.

  • Side

    Side

  • Other side

    Other side

  • Face

    Face

  • Small parts

    Small parts

  • Square off the cap and back

    Square off the cap and back

    The cap should come to a nice square corner, right by the back end of the trap.

  • Test fit, side

    Test fit, side

  • Hero Forehead

    Hero Forehead

    The hero style helmets had lower brows. Don't know what hero helmet means? Go to http://www.starwarshelmets.com. Go on, I'll still be here when you are done!

  • I went stunt with this build

    I went stunt with this build

  • Eye, rough cut

    Eye, rough cut

    This is what it looks like after cutting out the eye with that cutting bit

  • Eye, hand cleaned

    Eye, hand cleaned

    Once cooled, I pulled off the excess plastic.

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    Full Kit
    Cap & Back
    Trim the excess flashing off the face