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How To Assemble Boba Fett Helmet 2017-08-06T04:52:46+00:00

Preface

When assembling the FPH2 helmet, there are many ways to do it. This is my way that I do, the way it was designed to function with the various parts. When looking at different people’s kits, I always find that some may have a more extreme way of putting the kit together and some have a “quicker” way of assembling the kit. Feel free to use different tools if you want. I use these tools, because they are simple to use and are available anywhere.

FPH Boba Fett Helmet
FPH2 Boba Fett Helmet
FPH2 titled Boba Fett Helmet
FPH2 Straigh On View

Tools for FPH2 Assembly

I have put together a list of tools needed for assembly.  If you have the tools there’s no need to go out and buy new tools, unless you’re looking for an excuse.  If you do need a tool, I have provided links to the recommended tools (it is an amazon affiliate link, all profits support my jetpack habit).

Amazon
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Amazon

Visor

You will cut this area out with a Dremel Cutting Tool and finish it off with a file. Save the middle area since you will need this for the keyslot area. An easy method for attaching the visor is simply using a high temperature glue gun and gluing the visor on, more complicated methods can be used and can be found at The Dented Helmet.

Pieces cut out from the Boba Fett Helmet T Visor

Ears

Here are the 4 ear pieces that you will need to attach on the helmet. I use a glued in bolt method which makes the ears detachable for convenience. The first thing you will need to do, since you will be painting it also is to make sure all the edges are free of flashing. Flashing is the extra urethane that flows over the mold as it is being created. Go ahead and sand these down with some rough 100 grit and if there is a lot, use a file.

Picture of Boba Fett FPH2 ear parts
Picture of inside the FPH2 Boba Fett Helmet marking the holes for the left ear piece

Left Ear

Let’s begin with the left ear. The long one. What you’ll be doing is making two marks on the inside of the helmet of where you want the screws to be place. Evenly space them so that they are on opposite sides of the ear.

Right Ear – Lower

On the right lower ear, you’ll be doing the same thing so put two more marks on the inside of the helmet. Once you are done with marks and are happy with their placement, go ahead and drill the holes through all four marks.

View of inside the FPH2 Boba Fett Helmet looking at the lower right ear markings

Matching The Ears

Place the ear where you want the ear to sit and with the ear sitting on the helmet, place another mark through the hole so it touches the ear. Do this for all four marks. Once you are happy with where the ears sit, place the ears on the table.

Making sure the ear piece and helmet piece line up correctly

Setting the Pocket Screws

In this step, you will be adding pockets for the screws to sit. So, you’ll need to take your dremel and a bore bit. On your ears, you will have the marks you made. This is where the center of the pocket will be. Take your dremel and bore a pocket about a 1/4” deep. Take one of the 8-32 screws and place it in there. Once it is deep enough, do it for the next 3 pockets.

Creating the pocket holes for the screws
Setting the pocket screws with glue
Pocket screws glued in place
Dipping the screws into the Super Glue Baking Soda Mixture

You’ll be gluing these screws in place with a mixture of baking soda and crazy glue. This stuff hardens real quick and a lot of people use it for quick repairs and filling in tiny holes in stuff. Place the screw in the hole and add a little bit of crazy glue. Next add a little bit of baking soda and with your finger squeeze and compact the baking soda into the hole. The mixture should harden almost instantly. Blow the excess powder out and repeat the process until the pocket is filled. If you overfill, don’t worry, file the rest of the excess off so that the mixture is even with the actual ear surface.

Fitment

Check to see if the ear fits. It should, hahaha. If it doesn’t, well you suck. Just kidding, bore out the hole in the helmet so you can adjust where you want the ear to sit. Once you find that magic spot, use the nuts and washers to lock the ear in place.

Fitting the ear piece to the FPH2 boba fett helmet
Showing the ear piece correctly installed from the inside of the FPH2 Boba Fett Helmet
Outside view of earpiece successfully installed after a little Mandalorian elbow grease.

Inner Ear

The Inner ear. I actually only attach this ear with the lower hole and the hole where the stalk goes through. If youll be running a servo for your stalk, I suggest adding another hole and screw on the upper part of the ear. Take the inner ear and drill through the urethane. On the back of the ear, use a countersink bit and add them to the holes so the 4-40 head can sit flush. Now, place the screws inside the ear and attach the nuts. The nuts will align with the outer ear cap and the out ear cap will press right in. . Next drill out the holes on the helmet body for the mounting screws (long 4-40 screws). Once that’s drilled, place the inner ear on helmet and attach the screws on the bottom. Take your RF stalk and place it on the inner ear and attach it with the screw, nut and washers provided. After this the ear cap should pop right on, if the nuts are lined up correctly.

Boba Fett Inner Ear
Hold Drilled into Gel-coat for inner ear.
bolts installed on inner ear
Ready for RF Topper, damn the helmet is starting to take shape.
Metal stalk installed, this thing is going to look awesome!

RF Topper

The RF topper will have to be sanded down to get rid of the urethane flashing. Also the holes on top for the RF light will need to be cleaned up with a round file. Very easy. Once that happens you can paint the topper with flat black and either glue the clear Perspex block onto the topper or use ¼” magnets to attach the block so you can remove it if you want. This is good if you are planning on adding lights to your RF topper. Also line up the screws to the topper and drill out some holes for attachment.

Excess material from the mold, some more Mandalorian elbow grease will fix this.
Boba Fett Range Finder
Holes for Boba Fett Ranger Finder LEDs
Range Finder Installed on FPH2 Helmet
Range Finder Topper painted black.
Range Finder painted black with mounting holes drilled.

Polaroid Lens Frame/ Lens

The Polaroid lens frame will have to be painted black and cleaned up/sanded. Once done, place the small lens inside the frame and crazy glue. Then crazy glue the whole assembly to the clear block.

Boba Fett Polaroid Lens
Boba Fett Polariod Lens painted black.

Keyslots

Very easy. Very tedious. Drill the center of the “T” area. Next use a jewelers file to file out the indented “T” area.

Key slots drilled out, this is the easy part.
Key Slots all filed out, take your time and get this right.

Borden

The RF topper will have to be sanded down to get rid of the urethane flashing. Also the holes on top for the RF light will need to be cleaned up with a round file. Very easy. Once that happens you can paint the topper with flat black and either glue the clear Perspex block onto the topper or use ¼” magnets to attach the block so you can remove it if you want. This is good if you are planning on adding lights to your RF topper. Also line up the screws to the topper and drill out some holes for attachment.

Placing the Borden into the Drilled Hole.
Borden installed in helmet, inside view.
Borden successfully installed on Helmet.

MQ-1 Calculator

Glue the back of the upper part of the calculator behind the keyslots. The bottom part is the piece you saved from cutting out the visor.

MQ-1 cutout from T-Visor
Pieces cut out from the Boba Fett Helmet T Visor
You have successfully finished the best Boba Fett Helmet Available. Happy Trooping!