Killonious Captain Rex Helmet Modifications

thingiverse

The original design for Rex's rangefinder base was simply a static decoration that didn't serve any purpose. I wanted to create something more functional, so I started brainstorming ideas. Drilling a hole and using a bolt wasn't the best option since it wouldn't provide any stops to keep it in place. I decided to take a different approach by remaking the base in Fusion 360. This allowed me to add some essential features such as a vertical/horizontal stop on the back side, space for a captive M5-.80 x 25 hex bolt, and a plug to hide the bolt. I also created a negative of the stop that could be used as a template to cut out the hole in the helmet. In addition, I designed a greeblie for the rangefinder stalk that added some extra detail to the model. V2 Update: After reconsidering my approach, I decided to make some changes to improve the design. Instead of using a template to cut out the hole, I printed a thin plate in the correct shape. This allowed me to hog out enough material to clear the hole, leaving just enough to hold the plate in place. I adjusted it so that the shaft would sit perfectly vertical in relation to the helmet and glued it in place. The result was a full 90-degree sweep when completed. I also hollowed out part of the plug to accommodate a captive nut instead of the original captive bolt. Update: April 14, 2019 I added some new features to my design, including breather/aerator/microphone mods that enabled me to use actual screen for the center. I also created a frame to go on the inside of the rangefinder, which made it easier to detail out a display screen. To complete the look, I added .SVG files for cutting paint stencils in Jaig eyes, side vents, and rear circle details.