For example in order to fashion the spherical depression in the nose, a length of metal rod was used in combination with a spherical dolly.
#Darth vader voice mask series
Robert made a series of custom die and shaping anvils. Various autobody hammers and dollies were used to shape and form each piece.Ĭustom builds like the Darth Vader helmet often require and extra does of ingenuity to get the job done. At the other end, the hammer when used in combination with a dolly flattens high spots while retaining panel contour. The pick end enables pinpoint accuracy when lifting or peening detail in the metal. Tin snips were used extensively to cut pattern pieces and trim away excess metal.Īutobody hammers are very versatile tools. Aviation style tin snips were used to make quick work of trimming out pattern pieces and truing up the contours around the perimeter edges. Now for a look at some of the tools-of-the-trade and custom forming jigs used throughout the build process. Darth Vader mask feature by feature build montage. The build sequence is actually from the bottom right to the upper left. Have a look at the assembly montage below. Intermittent tack welds were used to hold pieces in place. Paper templates and sharpie markers used to create flat patterns and to help accurately trim excess metal.Īs for the build sequence, Robert started with the cheekpiece working from the center outward to help maintain symmetry. Nope, we’re witnessing analog at its best! Robert uses a Shapie marker, paper, and a healthy dose of hand-to-eye coordination, to layout his 2D patterns. I’m talking no 3D CAD, CNC lasers or 3D printers. GPP looks to kick it old-school for the most part. The sheet metal is stretched and force into the proper shape one blow at a time. It requires plenty of strategic plows! Also, you’ve also gotta be able to look at a flat pattern and see the resulting 3D shape before you lay hammer to metal. It requires a fine balance between force and finesse. Shaping metal is not for the faint of heart. – source skull cap, facemask, and chin/neck cover To make the forming of small pieces easier Robert could be using upward of 22-gauge (0.0299-inch). More than likely, the thickness of the metal is 18-20 gauge, which equates to 0.0478 inches and 0.0359 inches respectively as these are common thickness used in autobody repair and restoration. Robert omitted a rear neck cover most likely to make it easier to don and doff the helmet. The helmet is constructed of three major components, skull cap, facemask, and chin/neck cover. Hop over to his GPP Facebook or GPP Instagram pages to view his entire sculpted helmet collection and more work-in-process. Each build, outdoing the other at showcasing the depth and breadth of Roberts skill at shaping metal. Not just Darthy, but I’m talking, Boba Fett, Stormtroopers, and Kylo Ren. While he delves a little in the Marvel and DC Comic universe, he’s spent the largest chunk of his time hammering out Lucas Film characters. His build collection is truly impressive. Robert is the owner of GPP and best I can tell he’s an autobody guy by day and a custom prop maker by night.