After starting this project during the Thanksgiving holiday last year (2006) I have finally finished my 2nd, Star Wars Clone Commander Helmet, known by hard core helmet enthusiasts as the Inclement Weather Helmet (I.W.H.). This helmet debuted in the film Revenge of the Sith (2005) worn by Jedi terminator Commander Bacara. I first wore this helmet (at the 95% stage of completion) at Star Wars Celebration IV in L.A., during Memorial Day Weekend 2007, and AdventureCon in Knoxville, the following weekend. 
This particular helmet started off as a simple Master Replicas Basic Edition. I originally intended to use this particular helmet in the Fall of 2005, except the officially licensed company was having quality control issues in China, pushing back U.S. delivery dates endlessly. I placed my order at CIII in the spring of 2005, which I canceled after much frustration. That's the primary reason I went with the fanmade JavamonkeyV3 (my first version of this helmet type) in February of 2006; it was a place holder until such time the M.R. Basic were to actually become available.
The reasons I went with Commander Bacara's armor as my official entry for the non-profit costume group, The 501st Legion of Stormtroopers, was three fold. One the name; as an homage to the Bacara Resort and Spa (12 miles north-west of my hometown of Santa Barbara) an exclusive destination, frequented by famous and powerful people from all over the world. This resort is beyond 5 Star, with it's own digital sound and film editing studios, for vacationing film producers and recording artists. I was on the ground floor as a board member of the local Chamber of Commerce when the resort was officially opened in 1999, and I have many fond memories of the Bacara and the social-charity events that I have participated there, over the years. Secondly, the fact that Commander Bacara's helmet closely resembles the look of the original Imperial Snowtroopers (The Empire Strikes Back, 1980). The snowtroopers were my favorite troopers from the original trilogy. Finally, Lucasfilm's design philosophy behind Commander Bacara. The idea being that he, along with clones of the same background and accoutrement's, are templates of the first true Imperial Stormtroopers, setting the tone for the Empire we all know from the Original Trilogy.
As you can see, the picture of the subject helmet to the left looks different than the one above, as the removable faceguards are in place (attached via rare earth magnets) This was done by design, as I wanted to only have one helmet for both my Commander Bacara and custom Voltaire costume, respectively. My custom Commander Voltaire and Bacara were both to share the same exact helmet to spec, as the initial intent in the beginning with Voltaire was a more obvious, direct hybrid of Bacara and the classic snowtroopers.
The major problem I had with my JavamonkeyV3, back in early 2006 (my first helmet) was that I could not engineer the plastron faceguards to cover the sides of the helmet (again, as seen to the left). So, I went ahead without the guards, to meet a deadline for a TDH photo shoot (April 28, 2006). After the shoot, I realized how cool the I.W.H. looked without the faceguards in place. Plus, it was clear after analyzing the I.W.H., the faceguards were meant to be detachable anyway. So, the idea shifted to where Commander Voltaire would wear the same helmet as Bacara, sans the faceguards. As a note of importance and acknowledgment, the faceguards on this newer helmet were ultimately made by EVO, a fellow 501st member and very talented prop maker. Of the 5% remaining details that finished off the helmet project, all were small in comparison against the massive, time consuming modification process involved in converting the base helmet, into this variant I.W.H. Of course, as the old saying goes, the devils in the details.
One of the aspects that needed to be finished on the helmet was the topical weathering effects and battle damage. The picture to the left, shows finished weathering around the right side communications mandible. In attaching the respective mandibles on the helmet valance, or neck guard as they are called on ancient Samurai helmets, I had some areas where these mandibles did not mate exactly flush. In which case, I was left with gaps. The cool thing about weathering and creating battle damage, is that you can almost always turn a negative into a positive, by incorporating defect,s and dressing them with simulated dirt, grime and rust build up. In the case of the minor gaps, I used black plumbers epoxy to fill and, set-up a simulated collection of grease, grime and rust.
Once the black epoxy dried (about 15 mins) I brushed in a coat of French's Mustard (yes, the condiment LOL) I then used a blow dryer to quickly dry the mustard, wherein I brushed a light coat of Model Masters Rust, over the black epoxy. The mustard serves as an organic base for the rust color. I then dabbed away with a paper towel, lightly dipped in thinner, to create a natural effect. I repeated the entire process once. The end result is what appears to be a combined, swollen build up of grime and rust. I used this technique subtly throughout the exterior of the helmet. Bacara is technically a Galactic Marine, so I went with the idea that not only would he fight in harsh cold environments such as Mygeeto (Revenge of the Sith) but in water and desert environments throughout the Galaxy, where fast, devastating attacks are required.
Other weathering techniques were employed such as "washing". This is where you take particular colors to highlight depressions and other fine details, such as assembly joints and areas were grime, mud and other elements would ultimately settle, over time. In this picture to the left, I used real earth mud as my wash. I applied it thick and liberally with a paint brush, then I used a paper towel to remove 98% of the excess, until I had the desired effect. Once the effect was in place, I sprayed a light coat of Testors Dull Cote to lock in the effect. This stuff takes time and practice, but the end result is outstanding.
Now, here are one of three unusual things that I have done with this helmet, and this would not be considered "film canon" (canon is a term for exact specification of an item or a story element, as actually seen in a film) and that is the black Heat Dispersion Vents within the indented cheek area (above). These are also simply called "tube stripes". These stripes are from a set of Imperial Biker Scout decals (Return of the Jedi, 1983) I picked these up off E-Bay. The heat vents on virtually all Phase II clone helmets are much bigger, and are placed a tad further down along the rounded "tube" area of the helmet. Considering that we never see in any official canon images (either from the film or pre-production) as to what Bacara's helmet looks like underneath the faceguards, I took the liberty to modify the look. This modification is designed to further enhance the unique look of my custom Voltaire costume when the faceguards are off, which said costume doesn't exist in any Star Wars film to begin with. Also, the applied science here would be that with the faceguards on, heat would have to be dispersed alternately anyway, solidifying this modification as reasonable and justifiable. At least in my book.
The second unusual thing I have done to the helmet was modify the Air Supply Intakes, or "aerators", on the bottom left and right sides (the black circular nozzles, image left). When I received the M.R. Basic, I was not happy with the overall look and design of these intakes. I felt they were to squashed looking, and lacked any real design character (not on M.R.'s part) Part of the problem in creating all Digital, "costumed characters", is the loss of the sense of realism when your not designing and tangibly solving issues of functionality. That's where I personally feel that real costumes should have been made for the newer Star Wars film series, over digital. The original Stormtrooper costumes were real, and the old school methods that were used, is what gave everything that based in reality feel. For instance, the Air Supply Intakes on the original Stormtrooper helmets were Microphone tips manufactured by a company in the 60's and 70's called Hovi. They are perfect, as they have that Star Warsy edge.
Here in this picture are two sets of replicated Hovi Mic Tips, one set from Tim Allen (SoCal TDH member) and one set from Keith (in the U.K.) of the 501st www.whitearmor.net. I believe the tips Tim sent me were made by Keith originally, as well. Also in the picture, is a set of hollow, CNC machined, metal clone intake bases. What I did here was combine the two different styled elements to create a one-off, hybrid Air Supply Intake. I simply cut the replicated Hovi mic tips in half (they are made from resin) and positioned them into the clone base, presto.
An upgraded look with more character. I used left over plumbers epoxy to fill and meld the elements together(from behind, which is hollow) for a permanent fit. Acknowledgment and kudos again to EVO for the machined bases. I also blackened the silver mesh screen with burning, oily styrene plastic, for a good combat residue effect, locked in with a light coat of Dull Cote. Then, a little dry brush with silver enamel paint for final finish.
The last unusual element is actually canon, and that the would be the helmets Communication Transmitter, in the chin area. This is one of the design elements that Lucasfilm incorporated into the Bacara helmet, that is a direct replication of the versions seen on the original Stormtrooper helmets. Further solidifying Lucasfilms design philosophy behind the character.
Here in this image to the left, you can clearly see the new transmitter installed. And again, thank you EVO for creating this part. Also, in this image, you can see a set of 3 Heat Dispersion Vents (the same style of Biker Scout decals) on the bottom of the faceguards. This also film canon, and are equally placed on the right side faceguard.
Well, there you are my friends. This was a rewarding challenge to say the least. I learned alot about helmet construction, more so on this project than my first attempt on my original Javamonkey version. Of course, as soon as I started work on this M.R. based helmet, a better, far more superior base helmet has since hit the scene . Naturally, I am now inclined to make the ultimate version. Third time is a charm, right ? LOL!
I have uploaded over 50+ images in 2 photo albums dedicated entirely to this M.R. helmet conversion. (right sidebar)
Happy Holidays!
The Commander
