Minbari Warrior Reduced Bone Crest

Minari warrior reduced bone crest. 3D printed and padded with foam.

• Multipurpose foam. Something like this
• Glue gun and glue sticks. Something like this. Pain-sparing tip: don't get the gun from a crafter supply shop, get one from builder supplies.
• Scissors. Pain-sparing tip: use sewing scissors, those designed for cutting fabric, not paper. It will save you time and nerves.
• Soft tape measure. You can get one from your local sewing supplies store.
• Skin colour paint (optional). Something like this.
• Bone Crest and fitting rings 3D models from here.
• 3D printer or you can use one of the 3D Print Shops in your local area.

Measure your temple gap - the straight line distance between your temples as shown in the picture.

The default size of the Bone Crest (temple gap) is 137 mm.

If the size is really off - to the point where it cannot be adjusted with the foam padding, i.e. more than 10 mm bigger than your temple gap, or if you really want it to fit tightly, use the fitting rings 3D models provided. Print them and see which one fits your head best.

There are 3 rings provided - small (116 mm), medium (130 mm), and large (142 mm).

Find the ring that gets stuck on your head and the one that goes freely on and off. Note their temple gap sizes.

Use the 2 numbers you've got from the previous step to calculate the Bone Crest Scale.

Let's assume that the medium ring (130 mm) gets stuck on your head and the large one (142 mm) goes freely on and off. Also, let's assume that your temple gap measurement is around 138 mm.

Take the large Bone Crest Model as a basis - in this case bone-crest-142mm.stl.

You need to figure out how much you need to scale it down.

The medium ring is (100 - (142-130) / 142) ~ 92% scale of the large ring.

Your measured head is (100 - (142 - 138) / 142) ~ 97% scale of the large ring.

Eyeball it and add/subtract 1-2% more or less to that scale estimation, in this case, 97 +- 2%.

Grab the corresponding 3D Model from here. Print it scaled to the number calculated above. The plastic colour you see in the photo is Bone White.

Cut out the padding pieces from that foam. They can be filling the entire internal surface of the Bone Crest or be as small as in the photo, depending on how tightly you fit the size.

Glue them onto the internal surface of the Bone Crest with the glue gun. The internal surface is completely flat, so the basic shape of the padding is simply a strip size of LxWxT, where

Length is the internal diameter of the Bone Crest from temple to temple. Use a soft sewing tape measure to measure it.

Width is the height of the Bone Crest. Depends on the scale.

Thickness depends on how tight you want it to be. Start with 20 mm, you can trim it with scissors once it is glued on.

Paint the padding to match your skin colour or the colour of the Bone Crest with simple water-activated paint or acrylic paint.

And you're all set. Congratulations.