UPDATE FEBRUARY 6, 2011:  WE HAD PRODUCED OUR FIRST SHIPMENT OF THE X-WING HELMETS, BUT UPON INSPECTION, WE WERE NOT SATISFIED WITH THE QUALITY OF THE VACUUM FORMED VISOR (WHICH IS THE WAY THEY WERE MADE FOR THE ACTUAL PROP.)  IT WAS VERY DIFFICULT FOR THE VENDOR TO CLEANLY TRIM THEM WITHOUT RESULTING IN A POSSIBLE SHARP EDGE.  WE HAVE THEREFORE DECIDED TO MAKE AN INJECTION MOLD FOR THE VISOR.  THE NEW MOLD WILL TAKE APPROXIMATELY 4-6 WEEKS.  UNFORTUNATELY, THE FACTORIES ARE CLOSED FOR THE CHINESE NEW YEARS HOLIDAY.  WE WILL UPDATE THE SCHEDULE UPON THEIR RETURN.

Here are some pictures of the progress of the helmet.  These pictures also show you the process that we go through in order to make our replicas.

We are still targeting to start to ship these helmets from Asia in late January.  However, there is always a chance (OK . . . a VERY good chance!) that we run into a delay in our never ending pursuit of making the most accurate replica possible.

1.  We have already molded most of the helmet shells.  They are sprayed primer gray which makes it easier to see any defects in the surface of the fiberglass.

2.  Once inspected and free of any surface defects, they are sprayed white.  These helmets have been sprayed with the first coat.

3.  We make a B/W version of all of the decoration and then place it on the helmet.  This step serves several purposes:  First, it used to make the spray masks and the tampo printing plates.  Then, some of the artwork is distorted to conform to the curved surface of the helmet.

4.  These are the preliminary design of the internal padding.

5.  The color version of the artwork

6-9.  The first factory decorated helmet (note singular, not plural!)  This has not yet been given final approval by either us or Lucasfilm.