Boba Fett Visor Tips

No matter how good of a job you do on the paint, if you don't replace the standard visor, your helmet will look terrible. The best way to do this is to contact Richie from Richie's Armor. He can provide you with a great replacement visor.

Replacing the Visor Yourself

Another way to replace the visor would be to purchase a protective full face shield and cut it to fit your mask. Face shields that are pre-tinted are available through some stores like Sears. These shields can be found with the bench grinders, or with safety equipment.

You can also try Lab Safety Supply. Look for the "Shade 5 Replacement Window", item number: WQ-18753-2. These visors (minus the headpiece) run about $20 plus shipping. The visor itself is dark green (kind of like Ray Ban sunglasses) but no one but you can tell when you're wearing it. The visor is also very dark from the front, but you'll still be able to see clearly.

Note: We definately do not recommend buying a clear visor and using window tinting on it. The tint is made for flat surfaces (like a car window) and the visor is very, very curved. You'll wind up with alot of bubbles if you're a novice at installing it.

Installing the Visor

Begin making cuts in your Don Post helmet as outlined to the right. Use the cutting disks that came with your rotary tool.

Now, you'll want to cut your visor to the desired "T" shape. Once again, using your rotary tool, make the desired cuts in the shape of a capital "T". You'll need to test the fit of the visor to the helmet several times to make sure you get it right. Remember, to cut the visor larger than normal and to make smaller cuts from there. Don't ruin your visor by cutting too much material off in one shot.

Once you have finished cutting the visor, use a rough grade of sandpaper to "rough up" the spots where the helmet and visor will meet. This will give the glue something to adhere to.

To date, we've only found two kinds of adhesives that will stick to the mask. 5 Minute Epoxy and Hot Melt Caulk. The epoxy can be easily found at hobby stores and home improvement stores. Here's the problem with it: when the epoxy gets hot, it turns back into liquid. If you leave the helmet in the car for any amount of time, during the summer, the epoxy will let go!

To read more about Hot Melt Caulk, visit the Basic Tips section.

Securing the Visor

Once you've replaced your visor, you may find it to be a little wobbly.

This brace is made from 1/16 inch aluminum, which bends easily by hand.  Drill holes in the metal using a hand drill and then drill the holes in corresponding places on the inside of the helmet.  Tap the holes in the helmet with a 2-56 tap and thread the screws in from the back. Before you screw in the screws, glue the brace to the visor.  In the second picture, you can see how the helmet looks from the front. You can fill these holes and paint them if you like, or just leave them as they are.