In this Chapter I will be building Mando's iconic helmet.
A portion of this video is sponsored by Omaze enter at omaze.com/hacksmith
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Welcome to Chapter 3 of our Mandalorian Series. Over the next couple months Hacksmith Industries
will be piecing together our very own Mandalorian suit but we aren't just stopping with the armor
we'll be including some of the weapons and a few other special builds as well.
All leading up to an epic finale where I don the suit for the first time and put it to the test.
You definitely don't want to miss it.
In Chapter 2 Bogdan and Caleb made the blaster and spear. Before that in Chapter 1,
I built Mando's flamethrower.
If you missed any of it there are links in the description below.
With the blaster and spear complete Bogdan
and Ben have turned their focus to something very exciting, Baby Yoda.
I mean, The Child.
I mean, Grogu.
Specifically his preferred method of transportation.
I know it's not technically part of Mando's suit but we couldn't resist and if you can't
resist the urge to watch that Chapter it's available right now! Exclusively to members!
If you're not already a member and want early access to that video
and future Hacksmith videos, click the link below.
When it comes to the Mandalorian it's the helmet that's the most iconic.
Ever since Boba Fett appeared on our screens in the Empire Strikes Back
fans have been drawn to the Mandalorians. The amazing cult-like following the supporting
character gained is what eventually led to the Mandalorian as a series
and no piece of tech or armor is more instantly recognizable than the helmet.
It better be I guess he never takes it off.
If I don't get this helmet right the entire project will suffer so there's lots of pressure.
Like most projects it all starts off with the design.
How are we going to design Mando's helmet?
I actually bought this replica helmet which we're going to use as reference.
It's really quite complicated with all those curved surfaces
which is going to be a real challenge to manufacture, especially out of Beskar.
As always we'll be using Solidworks to do the actual design.
So we've got the front of the face plate now and we're just going to give that a nice curve.
Let's design the rest.
Looking pretty good!
So we've got most of the helmet designed now.
As you can see I've got all the features around the outside
of the helmet. Now the thing we're missing is the dome.
How are we going to make a metal dome?
The obvious answer would be to cast a shape like that.
Unfortunately we don't actually have any casting facilities here at Hacksmith Industries
so we're going to have to try and think outside the box.
Sheet metal dome fabrication.
Ah and look at that.
You can make a dome with a bunch of triangles.
If you make a triangle in this shape where each section
is a dimension k which is radius divide by 2.56.
When you curve it, they actually line up together to allow you to make a metal dome.
Hypothetically if I create a circular pattern.
They should all go together just like this picture, so let's see what happens.
And look at that, it's pretty dome like.
Let's make it real!
Alright so we have all the 12 gauge pieces cut out which means we can start forming them.
Luckily we just got a brand new roller,
which means we can actually create curves in sheet metal super easily.
This should match up fairly closely to the curvature of this which, it does!
Let's curve the rest of the parts.
So we've curved the dome triangles using the roller,
but the issue is this part also interfaces with a curve.
So we need to actually roll this the other way too, which we can't do on that.
So what I've actually done is created a bunch of sheet metal dies using our plasma cutter,
to use in a vice.
Which means we can actually put the piece in,
clamp it with a vice and give it that nice little bend so it fits perfectly onto the helmet.
I want to do a test fit so I'm actually going to use duct tape to hold these triangles
into the dome shape because that dome is really going to control the overall shape of the helmet.
So we can't laser cut all the parts so we're going
to go use our plasma cutter and our new CNC machine to make a few more.
I think that's the last piece I need which means we can start welding it all together.
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Alright that's definitely not my best welding but I'm not actually a welder
so luckily I have a grinder.
Alright there's one half of the dome which means I just need to make a second,
luckily I already have.
The next part we're going to make is actually the earpiece.
Now the earpiece is kind of cool because it's actually utilizing the laser cutter,
the plasma cutter, and our new CNC machine.
Now I have to just put all four of these pieces together
and we'll end up with something that looks just like Mando's helmet.
Alright we've got it all tacked together now which means we just have to weld the rest,
grind it flush, sandblast it again, fill in these relief bend cuts, and then it'll look like this.
Alright so now it's time to do one of the detail pieces which is this back part right here.
I laser cut all the parts but I'm not too sure how it's actually going to go together,
so let's see what happens.
Not too shabby.
I think I'm ready to start tacking up the entire helmet so it starts
looking like a helmet so I'm super excited.
probably could have made the ears a bit lighter you know
Alright now I just have to weld all those seams.
Tig welding is kind of like painting with a really fine brush.
It's really easy when you rest your wrist on the table while you're working
but when you're using a bigger piece sometimes you can't hold your wrist on that.
I actually made this wrist mount little thing
to support your arm while you're welding and it really works quite well.
Now we can start with some of the detail work.
We're on to the next step which means we can remove these ribs
I put in to make sure this curved nicely but now we need to actually do the cheeks.
So I'm going to take this grinder
cut these ribs off and then we can start fabricating those cheeks.
There's basically three different pieces and as you can see the top
one is actually curved in two directions.
I've laser cut out the parts I need I'm going to start by rolling this one cheek piece
but likely I'm going to have to bend and hit with a hammer in the vice to fit this exact curve.
Alright so that worked out pretty good.
Let's see if we can make it fit.
I just have a bunch of grinding to do.
Now we just have to put them together.
Probably as good as we're gonna get.
Sandblast and grind!
Do I look cool?
No?
Then what was the point Darryl?
What was the point?
Now I may not look cool but at least the helmet works!
Cool I guess the only thing left to do is make it a bit shinier.
So we're going to use this wire wheel brush to really give it a nice polish.
Alright I think it's done.
Now the sandblasting did actually hide some of the imperfections with the
grinding and the welding and whatnot but honestly I kind of like the way it looks.
I feel like if his helmet was actually forged out
of Beskar it probably wouldn't look as perfect as it does in the show anyways.
Now all we need to do is add a bit of detail.
We're going to paint a black line in here and in the earpiece like that.
The nice thing is I don't have to be too careful with this
because once I'm happy with the paint in the crack
I can just take a cloth with some acetone wipe off any spillover that I got onto the front surface.
The last step is the visor.
Now I'm probably gonna laser cut a few spares but in the meantime I think I'm
just gonna use the one from this prop helmet.
This is the way.
With the flamethrower, blaster spear, and now the helmet complete we are well underway to
completing the entire Mandalorian suit but there's a long way to go
and in chapter four Bogdan will be back with Ben to build the Baby Yoda cradle.
That video is available right now to members!
Of course if you aren't already a member and can't get enough of the Mandalorian build click the
link below to become a member and revel in all that early access glory for all of our videos.
This is the way, I have spoken.