The TIE Pilot Costume: Helmet

Other series of TIE pilot helmets were made in the past, and are occasionally available on the second-hand market. These include the three series made by Don Post Studios (the Deluxe, Classic Action, and Standard). The main difference between the Deluxe & Classic Action (CA) vs. the Standard is in the scale and size. The Deluxe and CA were larger in size and proportions than the Standard, which is generally only noticeable when compared side to side (visit Star Wars Helmets for in-depth comparisons and reviews of all models).

Out of the box, the Rubies helmet will need several modifications before it's ready for prime-time. Most noticeable will be the warped ear wells. Whether this warping was due to a faulty mold or whether the vinyl material simply cannot hold up to the weight of the helmet resting on this pressure point is unknown, but the ear well will need to be straightened out first.

Basic Modding:

1. Straighten the earwells.
2. Remove the bubble-lenses.
3. Repaint the helmet.
4. Apply new helmet decals.
5. Install flat lenses.
6. Install hardhat liner.
7. Install other electronics (fans, mics, etc.)

After shaping the ear wells, many pilots opt to repaint the Rubies bucket. This is a long, arduous process and absolutely cannot be rushed. Before painting, you will need the following tools and accessories:

• 600-grit sandpaper
• tack cloth (available in the paint tools section of your local hardware megamart)
• dishsoap
• masking tape
• newspaper
• a well-ventilated, dust-free environment
• Krylon Fusion gloss black

1. Wash the helmet in warm water (not hot, as hot water will warp the helmet you've so painstakingly reshaped already) and dishsoap for a clean surface ready for painting. Allow the helmet to dry.

2. Carefully mask off any areas you do not want painted. Lightly sand the surface of the helmet; not enough to scratch and gouge the surface but to give the surface enough tack for the paint to adhere.

3. Wash the helmet again and let dry for 24 hours.

4. Wipe the surface of the helmet with the tack cloth to remove any dust and debris.

5. Spray an even coat of paint. Although it will dry in about 5 minutes, allow the paint to fully cure for 7 days.

6. Lightly sand the paint with 600-grit sandpaper.

7. Gently wash off debris with a mild dish detergent and lukewarm water. Dry the helmet overnight.

8. Wipe the surface of the helmet with tack cloth again and repeat the painting process.

Krylon Fusion gloss black should not require a clearcoat layer. Some pilots use either a car wax or rubbing compound to add a high-gloss finish to the helmet. However, before using any such chemical compound, test the reaction of any finish with the paint on an unnoticeable area first -- chemical incompatibility is the number one cause of paint cracking, peeling, and orange-peeling.