Ring & Cap
The helmet of the Endor
Rebel Soldier or also called Rebel Commando, consists of two parts,
the helmet ring and the cap.
The helmet ring in its latest shape finished trials with wooden
We recognized soon, that it took too long time to cut it out, also
they were too heavy. It was incredible to imagine wearing those
helmet rings at long events.
I had the idea, to cut the rings out of Styrofoam and swaddle GRP
(glas fibre reinforced plastic) around it. My father dissuaded.
He suggested, we should make the rings with Styrofoam but coat them
with wood glue and swaddle them with gauze bandages. That also seemed
Thomas Jantschke and me a very reasonable idea. We began with the
photos from Episode 6 to assign the measures of the helmet rings.
So we assigned following: The ring on top should have a perimeter
The geometric basic shape of every ring consists of four semi circles
connected with two straight lines of 10cm. The rings are 3cm thick
and 3cm high.
In the angle of 15 degree, they were cut in- and outside, so a cone
shaped cross section arose. A total of four ring levels one upon
the other, connected with wood glue. The grouts were allocated in
this way that no grout was at the same position than the grout above
or bellow. So we achieved a maximum of stability of the basic corpus.
Now, an ample drying of the helmet rings followed for several days.
Then I grinded the basic corpus, so the rings had a homogeny surface.
Next, I cut from the front side at half height to the bottom at
1/3 from the back edge a bevel. Then, a deepening was cut in at
the back side. Finally, in side I cut a cavity, where later, the
ear protectors should find place.
Now, I coated the rings with wood glue and swaddled them with gauze
bandages. After further drying time, I coated the gauze bandages
with surfacer and grinded the rings. Finally, I painted the helmet-rings
turquoise-grey and the characteristic yellow-red emblems front right
and back the parallel black vertical stripes.
At the front side a peak of the cap, made of an aluminium plate
(sewed in green fabric), was screwed on.
The helmet rings are not connected with the caps. First, the caps
are caped, and then the helmet rings. It proved to be the most simple
and most comfortable kind to wear the helmets.
The greatest merit in building the helmet rings has Thomas Jantschke.
Indefatigable he cut very precisely and with great passion one ring
segment after the other from Styrofoam and glued the segments together.
At the same time, I built the rifles. I have to say, Thomas cut
me quasi dizzily. LOL!
All went "zag zag" his work, but all with cleanness and
precision. He nearly felled in love to the Styrofoam saw from the
Proxon Company and commended the device all the time, because it
cut so good and was variable adjustable.
From the ready basic corpus I took over. At this point, I want to
thank and merit Thomas!
Also a great thank goes to my father. He gave us the idea with the
wood glue and the gauze bandages. The incredible on the whole construction
is the enormous stability and the surface flintiness, which the
gauze bandages give the Styrofoam. You really have to hit the rings
intentionally with violence to destroy them. In ordinary use, the
helmet rings resist all pressures. So we got very light and solid
helmet rings and all in very short building time. 12 helmet rings
were built completely in two weeks.
The imagination, how the cap should be made, was found faster then
at the helmet rings. Again, many pictures from the movie were collected
in the internet and evaluated by us. The original caps were British
Pilot caps from the Second World War. To get those at payable prizes
would have been absolutely impossible. Those parts, you get only
at militaria-antiquarians and you can pay some hundred Euros for
it. So, Wladimir and I thought about what cap we can take for the
basic shape. Finally we came to the winter cap of the German Federal
Armed Forces in its elder unicoloured edition.
I first began to sew a prototype with hand. The ear parts I filled
with filling material used in pillows and Teddy-bears.
Wladimir liked the prototype but also some own ideas to improve
it. More later.
So we next went to a BW/US/NATO-shop, bought ten winter caps, got
another two winter caps free and enough fabric from old green shirts.
Then, Wladimir took over the part of the cap production. Wladimir
is a master in machine sewing, therefore his first cap was relatively
fast ready. His changing compared to the prototype was, that he
had the very good idea with the ear protector capsules. Therefore,
we bought the ear protectors (look like headphones), also often
called "Mickey Mouses". We pulled the soft rings and the
foam wadding out of the capsules and drilled the rings with 1mm
all around; therefore Wladimir could sew it on the caps. The quilted
top part was sewed with two layers of fabric with foam laid between.
At the side parts, he riveted a closing strap.
For the event at Media Market in February, the first costume was
For the German Model Masters in May, he sewed further four caps.
Then, I sewed four caps with hand, as we needed group photos for
our next event at Media-Market.