In the Judge Dredd comics, the Justice Department has a unit that investigates crooked Judges. The Special Judicial Squad (a.k.a. SJS) is part Internal Affairs and part Nazi SS … generally playing the villain role by persecuting Dredd on some trumped up charge.

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I was commissioned by a few members of the Judge Dredd Costume Group on Facebook to help design and then build a new version of the SJS helmet to go with their uniforms. They already had an awesome badge (designed by MisterXero on the RPF) so the helmet needed to complement the design.

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I never cared for the way the visor was replaced by two “evil” eye holes. It seems to me that the visor is a defining component on all the Dredd universe helmets and should NOT be deviated from. Working with the group, I produced a bunch of different designs exploring visor configurations, trying to stay close to the movie helmet while also paying tribute to the comic source.

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This is where we landed. The design has the signature faceplate and the trim mimics the comic book eye holes.

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Next I built the new design in 3D to work out some details. I rounded the center crest to transition from the skull emblem (the original 3D model used for the group’s badges).

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I found that raising your head while wearing a Judge’s helmet causes the back of the helmet to hit your neck roll and shift the helmet. To remedy this, I built a scoop into the back.

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Once everyone signed off on it, I brought the model into Pepakura and exported the paper model.

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I slush cast SmoothCast 300 into the paper model in several coats to build up a th1ck shell.

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Much sanding later, I had smoothed out all the paper geometry.

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I printed out the skull since I scaled and adjusted the original geometry to fit my helmet.

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A quick test fit on the helmet.

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Using Bondo, I added mass to the back of the skull so it would fit snugly to the helmet.

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The helmet was molded and I slush cast a copy. By the group’s request, I mixed aluminum powder in the first coat so that any scratches to the paint job would reveal metal.

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The skull emblem was cold cast with aluminum powder so it could be shined up to a real metal finish.

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After a base coat of flat black primer, I attached the visor with pop rivets.

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The helmet was given a gloss clear coat, leaving the trim matte black. the skull was epoxied in place.

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Judge Rotzler models the completed helmet.

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Judge Cho models the full custom leather suit produced by Reel Images Leatherwear. Check out the skull buttons and the badge on the shoulder. So cool!

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