Redditor Salok9755 is all about modding. He’s already transformed a Kylo Ren lightsaber, and now he’s morphed a Black Series helmet from Hasbro into a more screen accurate model. The $79 Kylo Ren helmet can be worn as is and has a voice changer, but Salok9755 wanted something more detailed. He wanted to remove the seams, repaint everything, and reshape it where necessary — for example, the face mask is too big and it’s all in a single piece instead of separate segments.
Salok9755 gutted the mask; he only kept the speaker part of the voice changer. He kept the front mask, the back, and the visor. It wasn’t the easiest think to take everything apart. He said:
The batteries for the voice changer were in the top of the helmet. I used my Dremel to remove as much of the battery area as possible, leaving only the bare minimum of material to use the battery lid to fill the hole. This is going to be a lot of work, and i didn’t trust glue to hold it. I applied glue to make it sort of stay it place (it didn’t really), then I ‘welded’ it in place with my soldering iron. Basically dragged it along the edges, very slowly. Melting the plastic and it quickly dried into 1 solid piece. Smelly as hell, but it’s a rock solid connection.
Visit this Imgur gallery to get details on the entire mod. Even if you don’t want a Kylo Ren mask, seeing the techniques and process is useful.