Jessika 'Testor' Pava - 2019 Update...

Well.....it's been a while and should really get back onto this project. My daughter did re-try on the jumpsuit last year sometime & yep, you guessed it, she'd grown in height. I obviously wasn't thinking ahead and had cut off the extra length in the legs as thought to use this material for pockets etc. So am going to have to start over on this by buying a new one.

The chest box I made out of cardboard, this was great fun to make. You can check out the start of this project here.

I have since then been asked by her if we could make a few other outfits so I need to source info on these and see if these are viable, easier/simplier/longer lasting lol

Jessika 'Testor' Pava - helmet - 2.5

Work done 19.6.2017

The inner 'ear' area, needed to be raised up to form a central pad area. so I glued in some cardboard to build this up and then applied filler to slope the edges.

To create the rear helmet details, I used Milliputty.

These are rough to start with.......

More updates on this project coming as need to redo some of the costume for my daughter.

Jessika 'Testor' Pava - helmet - 2.4

work done: 15.6.2017

Next up I started on re-doing the 'blast shield'. I'd already attempted this once, but wasn't happy with it, so decided to try again a different way. This is all new to me so I soon realised I had to think back words.... by this I mean that I make the shield, then make a cast of the shield, to then make it into a mold, just like the helmet.

Started off by making the shape using cardboard.

A few more layers of cardboard to make more rigid,

before applying fiber glass matt and resin.

Here is the first layer of fiber glass matt applied.

I added another layer on top of this to help strengthan.

Once this was dried I started to mix up and apply car body filler.

I ran out so this was all that was left in the tin.

pic....

Whilst waiting, I started looking at the details that I could add to the helmet to be included in the actual casting of it. Rather than have to stick extra pieces on.

I started on the cheek detail (circled in yellow below)

Other's have done these, so there was plenty of ref pics to work with.

And this was the mocked up version...in cardboard.

And here it is glued into place

I still need to fill in the gaps etc and then seal it before applying primer etc.

But it's looking good, and after all, this is for my daughter so scale is not 100%

Jessika 'Testor' Pava - Flight suit 2.2

Work done last year 13.6.2017.....Thought these following post's had been posted


Usual busy family weekend stuff, but i was able to re-make a start on the blast shield. Using a hot glue gun to get started, i cut out and positioned roughly where the sides would go. Next was over the top strips, cross strips, followed by larger flatter pieces.

The start of the cardboard strip framework.

Next then was to start applying fiber glass and resin to form the base of the shield.

Resin applied to framework.

The plan is to create the shield, then make a silicone mold to then create a slush cast from it.

Jessika 'Testor' Pava - helmet - 2.3

With my daughters timely reminders that I've not done any work on her costume lol, I got back on to working on her helmet.

I've been reading but mostly watching since I started this project, You Tube videos of how to cast helmets and this multi-part tutorial has been invaluable source of info for a first timer, budget build attempt at casting a helmet.

Click on the picture to take you to his You Tube Channel

He stopped posting due to work commitments but as his viewing numbers show, he has been useful to others.

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Here's the start of me applying cardboard around the edges.

I've also ordered some clay, and next will be to buy silicone tubes.

Am looking forward to this with each little step lol.

Jessika 'Testor' Pava - small update

Had to put this on hold, but not for much longer lol, daughters nagging me :D

Have got some elasticated material for the flight suit cuffs. It's just a case of fitting everything in, time wise.

Then once more free time is available, I'll make my first attempt at molding.....her X-wing helmet. Still work to be done before I get to this stage tho.

Jessika 'Testor' Pava - Flight suit 2.1

2017 and after Xmas/New Year am feeling positive about things.

With a free afternoon on Sunday, I got out my daughters flight suit and accessories and got to working on it again. I started by remeasuring her in the suit, yep, still fits lol. I then measured marked and cut off the excess sleeve & leg material. These bits I can reuse as pockets etc on the suit.

I left enough for hemming the edges and also the arms will need elasticated cuff material. There's also plenty of space and length to last her a few years growth lol.

I then led it all out for a mock-up picture.

There were a few bit's I'd misplaced for the straps, but for now, this is work so far.

Jessika 'Testor' Pava - helmet - 2.0

Helmet gets the chop!
25.11.2016

I really wasn't happy with the size. I know, I know this should of been sorted at the start, but I had hope things would work out.....

So after some thought, I marked out some cut lines and then used a saw blade and my Dremel cutter, to cut off the cheek/ear sections.

As my daughter was tucked up in bed asleep, I had to wait till the next evening to measure her head and test fit the separate pieces on her. I just hope this plan works and can salvage what I've made so far!

So the next evening, I dug out some foam and with some help from her brother, we managed to better fit the helmet cheek sections to the size of her head. I then measured the remaining gaps, height & width's to be able to cut & eventually, fibre-glass all the parts back together like a jigsaw.

Well, here's the start...

Measurements at the ready.

Additional cut lines for the dome section.

And then test fitting of the sides and the new cut down front dome section.

 Front view

Rear view

Feeling a lot more positive about how this 'rebuild' is going. This is ALL guess work regarding cut lines etc, tho so far so good lol.

December updates......Rogue One

Not posted up for a while, been busy working on and re-working Jessika Pava helmet.

Jessika Pava Helmet
It definitely needed to be smaller, which I posted up a while back, so have been re-working the size, fibreglassing, body fillering, sanding re filling ....repeat. The next plan is to go the cast route which I've been reading up on. You tube to the rescue lol, as i think this would be best. Wouldn't want anything to happen to the helmet and it be damaged.

Due to work issues, internet access has been restricted, and this was the only available free time I could update this blog, it will have to wait now till the new year.

Rogue One
WOW!!! I took the wife and kids to see the film on the Thursday (here in the UK) and we weren't disappointed!! It had everything a 'war' film should have plus it was Star Wars lol.
A lot of people have moaned about changes made, but personally i felt the film flowed and the continuity flowed though out. No spoilers, ill just say I wasn't disappointed and the kids enjoyed it too, which if kids get it, why can't adults ??? Lol.

Friday, was an early start and a long'ish drive to Milton Keynes, to meet up with fellow UK R2 Builders and Joker Squad. We were attending the iMax cinema's Rogue One day. Was great to catch up with everyone and raise cash for charity.
Will add updates and photos in the New Year.

There's another builders group day after Christmas to look forward too as well.

So for now, I'd like to wish everyone who follows this blog & has visited here a happy & Merry Christmas and a prosperous New Year. Lots of good things to look forward to in 2017, so stay positive people :)

Im now on instagram also on Twitter and Facebook lol.

Jessika 'Testor' Pava - helmet - 1.8 - Blast shield

17.11.16
The printed off template I had used for the blast shield, I wasn't 100% happy with. The shape didn't seem to match that of the helmet dome. I know this version was designed for use with matt, not cardboard tho. The sides are larger than they should be, just to add strength to the paper for when applying the fibre-glass matting.

I cut down the 'step' as looking at reference pics, it was to 'high'. Basically I just cut the distance in half.

I plan to fibre-glass the ends first to then be able to fix the blast shield in place on the helmet. This will, I hope, help with being able to then apply fibre-glass matting to the blast shield to get the correct shape.

Got both ends glassed up and also the leading edge to help keep the shape.

Helmet & blast shield test fitting

Which gave the shield enough strength to be placed on the helmet to test it.

As you can see the helmet has received some marking up. This is to guide me later with filler, shape & also to dremel to create ridges etc.

More work hopefully over the weekend.....

Jessika 'Testor' Pava - Flight suit & Chest Box 1.6

16.11.16
Started on painting up the chest control box.

Used some sample cardboard and applied paint to see how best to apply. Used a brush which didn't do so good. So my daughter suggested the sponges :). Applied a few layers to build up the coverage of white, allowing it to dry between coats, without it soaking in to much and warping the card. I didn't use any special paints, just kids stuff.

Once dry, I mixed up some white & black to get a dark grey. This I then painted into the grooves.

I then dry brushed over the edges etc to get the worn look. Next up was mixing some white & blue to get a light blue for the two buttons.

18.11.16
I've almost finished the painting now. Mixed up some white and black to paint the grey switch's.

X-wing TFA chest box, 95% painted

just one more button to be painted

Just need to paint the central button silver.

Jessika 'Testor' Pava - helmet - 1.7

11.11.16
When able to, I've mostly been applying filler to the helmet, sanding and shaping and repeating.

cheek section taking shape

I ran out of the second tin of resin, so need to get some more. Want to add more fibre-glass matt to really reinforce the helmets rigidity. I've had positive comments from work colleges which is always a good thing lol.

15.11.16
Picked up a new tin of resin Saturday, but wasn't able to do any fibre-glassing till Monday in work. The paper around the rear edge has seen a lot of action with handling of the helmet. Am also aware that the paper had started to break away, it hadn't bonded with the other paper. So as the fibreglass had already given the edge shape, so I ripped off the unstuck paper.

ripped off the unstuck paper

I'd had to do this in two other areas where curving the helmet meant taking the 'corners' off the Pepakura and so, took off the paper, which again, hadn't absorbed the resin fully. I didn't want the filler to come loose where it was thin. For this reason the inner areas of the helmet marked in black marker needed reinforcing.

Once this is hard I can carry on with applying filler to the outside.

16.11.16
Applied a second layer of fibre-glass & resin to this area to re-reinforce it structurally.

Whilst this was setting, I mixed up some more filler and applied it to the other edge of the rear crest.

More filler, sanding & filling to go.....

Jessika 'Testor' Pava - Flight suit & Chest Box 1.5

11.11.16
Forgot to post up the hose cap internal fixing pics. This should help prevent twist.

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12.11.16
Saturday I had five mins to sort out my 'electrical' box's lol, basically bags of bits an pieces. I dug out some battery holders & thought I'd quickly test the brightness of the LED.

The battery on the left is a mini 12v one, giving quite a bright LED.
The battery on the right is a 3v button type. The brightness was a lot dimmer.
(not to easy to see in the pics, due to the camera adjusting tho)

Next up is the painting.....

Jessika 'Testor' Pava - Flight suit & Chest Box 1.4

I found some spare ABS sheet that came with my FX armour, years ago. And marked up the ejector brackets for the harnesses.

These are scaled down to suit my daughters outfit.

The green LED arrived yesterday & so of course I had to fit it in to check.

 Inside of box showing LED (this will be hot glued in place)

& view from the front.

Next was to apply wood filler to the joins. Because the cardboard is layered up it's really stiff and so the filler actually works. Below pic is the morning after, once it had dried and was sanded.

I had to fit the hose on to show my daughter, who was very excited. These were taken before wood filler was applied.

 X-wing chest box & hose (which will be cut to length)