Making a Stormtrooper Helmet out of Veneer - Woodworking Talk - Woodworkers Forum
 5Likes
  • 2 Post By John Smith_inFL
  • 1 Post By Quickstep
  • 1 Post By johnedp34
  • 1 Post By fareastern
 
Thread Tools Display Modes
post #1 of 12 Old 04-06-2020, 03:00 PM Thread Starter
Junior Member
 
Join Date: Apr 2020
Posts: 5
View Sean Butler's Photo Album My Photos
Making a Stormtrooper Helmet out of Veneer

I found plans and a template to make a Stormtrooper helmet out of cardboard. Once the cardboard pieces are cut, assembled and glued, the helmet is then coated in compound, sanded, painted.

What I want to do is cut the many cardboard pieces as instructed, but then use the pieces as a template to cut thin wood veneer, glue the cut veneer to the cardboard pieces, assemble and glue together, patch the gaps with wood putty, sand, stain and poly.

Do you think it could work?
Will veneer adhere to cardboard?
If so, what glue to use?
Can thin veneer be bent/curled/twisted to wrap a curved surface like a helmet?
If so, what thickness?
Would wood putty work well-enough to seal the cracks/gaps?

Attached Thumbnails
Click image for larger version

Name:	4F21BE94-E600-4DC3-B5DF-59FD795DA5EE.jpg
Views:	19
Size:	147.5 KB
ID:	386961  

Click image for larger version

Name:	D2ACFB32-166E-4603-A173-4258520E9AD1.jpg
Views:	17
Size:	147.6 KB
ID:	386965  

Click image for larger version

Name:	840350B9-8E6E-424F-8DA0-8DCD56463642.jpg
Views:	15
Size:	150.2 KB
ID:	386967  

Sean Butler is offline  
Sponsored Links
Advertisement
 
post #2 of 12 Old 04-06-2020, 09:23 PM
Moderator
 
John Smith_inFL's Avatar
 
Join Date: Jul 2018
Location: Central Florida
Posts: 2,160
View John Smith_inFL's Photo Album My Photos
welcome to the forum

in my best guestimation, it will be very difficult to obtain a satisfactory
fit with real wood veneer attached to cardboard.
if you want the wood look, try the wood grained vinyl shelf paper.
less aggravation and much cheaper than veneer.
available at all your Box Stores and online in many styles.
even rustic pallet wood if that appeals to you.
you could make a better project and soften the edges with applications
of "paper mache" (strips of newspaper soaked in a diluted white glue)
and allowed to dry in the sun. then apply the faux wood vinyl.
Attached Thumbnails
Click image for larger version

Name:	71WiiU2haGL._AC_SX522_.jpg
Views:	15
Size:	55.8 KB
ID:	386989  

difalkner and Sean Butler like this.

I am a painter: that's what I do, I like to paint things.

Last edited by John Smith_inFL; 04-06-2020 at 09:28 PM.
John Smith_inFL is offline  
post #3 of 12 Old 04-06-2020, 10:06 PM
Senior Member
 
Join Date: Apr 2012
Posts: 2,886
View Quickstep's Photo Album My Photos
I’m slightly more optimistic than John. I think that thin veneer will conform to most of the shapes that the cardboard will. I would try to add the veneer as you build the helmet rather than build the whole helmet and then try to veneer it. I’d try to avoid the putty part - it won’t look good.

Veneer softener will help the veneer conform to unusual shapes, but you’re going to need to find a way to hold it in the shape you need and let it dry before gluing.

https://www.woodcraft.com/products/v...ner-tamer-pint


Also, I’m not sure if hot melt glue is going to work with veneer. Elmers or Wood glue might be a better choice, it you’re going to need a way to clamp it while the glue dries, maybe binder clips or spring clamps.

Good luck and let us know how it goes.
Sean Butler likes this.
Quickstep is offline  
Sponsored Links
Advertisement
 
post #4 of 12 Old 04-07-2020, 01:25 AM
Member
 
johnedp34's Avatar
 
Join Date: Jun 2016
Posts: 85
View johnedp34's Photo Album My Photos
My grandson would love this. Watch the videos on utube.
johnep
Sean Butler likes this.
johnedp34 is offline  
post #5 of 12 Old 04-07-2020, 03:50 AM
Senior Member
 
Join Date: Sep 2014
Location: East Anglia
Posts: 176
View fareastern's Photo Album My Photos
Have you looked at the model ship building world?There are people there with the knowledge to make very thin wood conform to all sorts of shapes.
Sean Butler likes this.
fareastern is offline  
post #6 of 12 Old 04-07-2020, 10:56 AM Thread Starter
Junior Member
 
Join Date: Apr 2020
Posts: 5
View Sean Butler's Photo Album My Photos
If possible, I'd like to go with real wood - I think I may dump the project if I would need to use shelf paper, though what you're saying makes sense.
What would be some of the reasons that you feel it wouldn't work?

Thanks!
Sean Butler is offline  
post #7 of 12 Old 04-07-2020, 10:59 AM Thread Starter
Junior Member
 
Join Date: Apr 2020
Posts: 5
View Sean Butler's Photo Album My Photos
Thanks so much, I appreciate your reply!

So what is it about the putty that you think wouldn't work? I have the same concern actually. In the original plan, he is compounding the whole thing, covering all the gaps - with my idea those gaps would be an issue. Also, since it'd be my first time doing it, the likelihood that my gaps would be larger/sloppier is pretty high.

Do you think the putty in the gaps would look crappy and really jump out in the way they break up the grain patterns?

Thanks
Sean Butler is offline  
post #8 of 12 Old 04-07-2020, 12:49 PM
Member
 
johnedp34's Avatar
 
Join Date: Jun 2016
Posts: 85
View johnedp34's Photo Album My Photos
I think I would get my son to investigate 3D printing. Could take a week to print
johnep
johnedp34 is offline  
The Following User Says Thank You to johnedp34 For This Useful Post:
Sean Butler (04-07-2020)
post #9 of 12 Old 04-07-2020, 01:00 PM Thread Starter
Junior Member
 
Join Date: Apr 2020
Posts: 5
View Sean Butler's Photo Album My Photos
Re: Ship-building - Great lead - thanks I'll check that out
Sean Butler is offline  
post #10 of 12 Old 04-07-2020, 01:03 PM Thread Starter
Junior Member
 
Join Date: Apr 2020
Posts: 5
View Sean Butler's Photo Album My Photos
Quote:
Originally Posted by johnedp34 View Post
I think I would get my son to investigate 3D printing. Could take a week to print
johnep
Yeah I really want wood - I don't want to wear this, I want it to sit on a table top and look beautiful. It's real wood or bust.
Sean Butler is offline  
post #11 of 12 Old 04-07-2020, 10:23 PM
Senior Member
 
Join Date: Apr 2012
Posts: 2,886
View Quickstep's Photo Album My Photos
Quote:
Originally Posted by Sean Butler View Post

Do you think the putty in the gaps would look crappy and really jump out in the way they break up the grain patterns?

Thanks
Because putty is always a single color, it will as you said, break up the grain patterns.
Quickstep is offline  
post #12 of 12 Old 04-08-2020, 03:57 AM
Member
 
johnedp34's Avatar
 
Join Date: Jun 2016
Posts: 85
View johnedp34's Photo Album My Photos
OK, if just to be used as a centre piece, I would look into CNC.
Probably a video of similar project on utube.


https://www.facebook.com/3beestudio/...0912406885353/

johnep

Last edited by johnedp34; 04-08-2020 at 04:02 AM.
johnedp34 is offline  
Reply

Tags
veneer, veneer flexing, veneer softener

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Woodworking Talk - Woodworkers Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

 
For the best viewing experience please update your browser to Google Chrome