The helmet proves to be
exceptionally heavy duty and highly durable for extensive convention use. While
the original helmet were constructed utilizing
a one piece dome and back piece, we discovered that such a technique produced a
helmet which cracked easily on the front of the dome and lower
edge of the back piece, where the tube curves inward.
For screen application, forming a one piece dome and back is much faster and
saves material, that is without question. After seeing so many of the lower
fan made helmets begin to crack and fracture, sometimes even before being
assembled, that method was not utilized for this specific helmet.
As you will see in the following images, the
dome and helmet back piece are much thicker and there is a brilliantly designed
recessed edge molded
into the upper region of the back piece. This means that when the dome is
mounted into place, the thickness of the helmet's interior structural seam is
doubled in strength.
This stronger interior seam prevents the helmet from flexing and also allows for
thicker plastic to be utilized on all sides of the dome and also the upper and
lower edges of the helmet back piece. This is perhaps slightly complicated, but
the end result is a much more durable helmet and I'm very pleased with it. True,
it is not 100% screen accurate,
but I would rather have something beautiful and durable for conventions and
appearances and I'll keep the slightly more screen accurate on display-only,
locked away from being handled, where it will not crack or fracture.
When the dome is applied to the helmet back
piece, the seam becomes nearly invisible and I really loved the clean, crisp
The following images were taken using studio box
lighting. The white high gloss finish of the ABS and the conversion of the
to a usable format caused some of the pictures to be slightly grainy, giving a
slight metal flake appearance to the plastic.
The Plastic is actually a very high gloss white and is quite amazing.
The small ridge as seen above and below is
actually an ABS cementing ridge, which when used while assembling the helmet,
gives the exact amount of lift from the face piece to allow the black UK trim to
be pushed under the lip or removed later on should
you wish to modify the helmet.
The right eye features the slight bump which is
sought after in 'stunt' helmets.
The photos turned a greenish-gray but the ABS
material is a very bright white and extremely glossy.
The depth and detail of the forming is
extremely high quality. Although the pieces were produced in .090 commercial ABS
The plastic is formed extremely well, capturing detail lost in many other suits.
The following two photos
display how the dome is attached to the helmet back piece.
Now, there is a reason why this helmet was designed in this fashion, and the
reason is strength.
The screen helmets utilized one single piece of plastic to form the dome and
helmet back piece. One big piece.
This made forming the helmets much faster and also easier but the problem with
this method is the stretching of the plastic
over such a large mold with negative recess on the back tube region and also the
front of dome. This negative draft makes the
plastic very thin on the front and the lower back edge. It also means the back
mold edge for the helmet piece is limited on how far under it will form,
which means the inside molded edge of the helmet must be trimmed quite high
along the tube region. Some fans like the helmet to have
slightly more ABS around the opening, making the opening slightly smaller and
not quite so large. Of course, you can trim this helmet as much as you wish.
The edge where the helmet
dome is cemented is extremely strong as the material thickness is basically
doubled, versus those helmets which feature a one piece dome and helmet back.
The helmet dome and back piece edge creates
a stiffening ring around the helmet which makes the helmet perfectly adaptable
for conventions where the helmet
is going to be knocked around, packed and shipped. Super durable, it's just
This recessed ridge is designed for the dome to
be cemented over. This creates an extremely strong helmet with a tremendous
amount of strength and durability.
The lower edge of the helmet back is much
deeper that other helmets I have seen, allowing each builder to trim the lower
to the height they prefer. Most one piece dome and helmet back pieces are
trimmed extremely high along the edges to accomodate the
part being removed the tool. This also causes extremely thin edges along the
front of the dome and the lower edge of the helmet back piece and the
helmet will immediately begin to crack.
The design of this helmet prevents cracking.