FULL METAL Mando Helmet! (HACKLORIAN: Chapter 3)

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   for your chance to win a custom Tesla  Model S and support some great causes. 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. Hey guys you know I love Tesla. We even built the world's  first half scale Cybertruck. So I'm super excited to announce that Omaze is  offering you the chance to win a Tesla Model S   customized by Unplugged  Performance and $20,000 cash. And yeah, unlike this one it's full scale. This dream car comes with  21 inch unplugged wheels,   cognac leather interior, and  a matte gray exterior wrap. It can do 0-60 in 2.3 seconds making it  the fastest accelerating production sedan   in the world, and don't worry taxes  and shipping are always included. All you have to do is go to Omaze.com/hacksmith  and enter for your chance to win. Use code HACKSMITH150 to get an additional  150 free entries to increase your odds   and every donation entry benefits a great cause. Like Givepower who creates sustainable  solar water farms that provide access to   clean water in water scarce regions around  the world or 501CThree a non-profit for   the younger generation focused on  energy, food, water, and shelter. They started out in flint with the Waterbox   program to bring people clean  water to communities in need. Much like our half-scale Cybertruck here the  Tesla Model S is all electric and looks awesome   with blackout trim, a carbon fiber rear  decklid spoiler, diffuser and side skirts. You can help save the planet and look badass  at the same time. Who doesn't want that? So if your chance to win this custom Tesla  Model S go to Omaze.com/hacksmith and enter   now don't forget to use our code HACKSMITH150  for 150 additional entries. Good luck! 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.

Channel: Hacksmith Industries

Views: 1,489,954

Rating: 4.9549489 out of 5

Keywords: thehacksmith, hacksmith, mandalorian, hacklorian, mando, star wars, disney plus, hacksmith mandalorian, starwars, pedro pascal, mandalorian season 2, mandalorian season 1, the mandalorian, the mandalorian trailer, grogu, baby yoda, mandalorian's sacrifice, wrist flamethrower, engineering, mandos helmet, helmet build, metal mandalorian helmet, full metal helmet, the mandalorian helmet build, beskar, beskar helmet, real life mando helmet, smithing, welding, custom mandalorian helmet, metal

Id: kgOx8lAj9J8

Length: 15min 2sec (902 seconds)

Published: Thu Mar 25 2021