A while back, I was contacted by another maker asking if I'd be willing to trade one of my Sniper Rifles for a few sets of his vac-formed marine armor. I agreed, but it doesn't look like his armor comes with helmets. Undaunted, I surfed my way over to the halo costuming wiki, downloaded the HD Marine pep file, and a few short hours and half a bottle of wine later I had the pep build knocked out.

The next day, I went ahead and coated the outside of the helmet with a thin layer of polyester resin (aka hardware store fiberglass resin):


Once the polyester resin had cured on the outside, sealing up all of the small holes where things might leak out, I went ahead and reinforced the inside with some black casting resin:

I added the black pigment to make it easier to see where I hadn't managed to slush the resin on the inside of the helmet.

(NOTE: you could just as easily go ahead and lay fiberglass mat and resin on the inside instead of the casting resin)

Now that I've built up enough thickness for the helmet to have some strength, it's time to start the bondo work.

Since I'll end up with more than one set of armor, I'm planning on making a mold and cranking out a handful of castings of this helmet.

Stay tuned...