How To Make A Helmet From Pep To Finish

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  1. #476
    Quote Originally Posted by tehjrow View Post
    Just to be clear, this is what you do:
    1.) Pepakura it
    2.) Paint the outside with resin
    3.) Rondo the inside
    4.) Rondo the outside
    5.) Sand
    6.) Paint

    I couldn't see in any video where you Rondo'd the outside of it. Do you just roll it around on the outside or do you use a brush?

    Also, how would you rate the strength of Rondo only vs Fiberglass? If it's just Rondo, is that strong enough to wear?
    No no no. Do not apply rondo to the outside, you will lose any and all details you wish to have. You simply use BONDO body filler to smooth out the areas that need to be smoothed (ie faces that are to be round but are faceted due to the pep geometry).

    If I were to rate rondo vs. fiberglass, I would say that fiberglass is stronger and lighter, but much more time consuming than rondo. If you need to harden your pep in a hurry and still want a good amount of strength, rondo is the way to go.

  2. #477
    Wait Something dosent fit? Dont you have to bondo or fiderglass the outside? I got bondo-glass to do te outside with it so it will be hard.As for sanding im still trying to find a tortial that has a video to show me everything i need to do

  3. #478
    how many grits?

  4. #479
    Quote Originally Posted by BioDelta View Post
    Wait Something dosent fit? Dont you have to bondo or fiderglass the outside? I got bondo-glass to do te outside with it so it will be hard.As for sanding im still trying to find a tortial that has a video to show me everything i need to do
    You put resin, alone, on the outside. This gives it just enough rigidity to be able to strenghten, as well as a proper surface for the finishing agent to adhere to. The fiberglass work, or rondo work, is used on the INSIDE to strengthen the helmet. After that is where the bondo comes in for the finishing stage.

    -Matt

  5. #480
    Sorry to ask this, I'm sure it's probably in this thread somewhere. But, how much of this process makes the helmet wearable? How much of it would need to be done differently to be able to wear this? Thanks

  6. #481
    Quote Originally Posted by Mypointyhair View Post
    Sorry to ask this, I'm sure it's probably in this thread somewhere. But, how much of this process makes the helmet wearable? How much of it would need to be done differently to be able to wear this? Thanks
    The entire thread makes a wearable helmet sir. This thread contains steps from Pep- finish, which includes hardening, molding, casting, detailing, etc. I know it's been cluttered up, and hi-jacked throughout. But I assure you all the information is contained with-in

  7. #482
    hi guys,i'm making a Mk VI helm and i finished the pepakura.now i'm stucking at fibreglassing.
    the helm will be brittle when i finished right?
    i've found a resin,but it seem to be not good

  8. #483
    This has been a great thread!! It's a one stop shop. Would have loved to see how the foamed chest piece came out. Great Info none the less!

  9. #484
    This is nice, and pretty smart, but I might just go with the lighter, and less expensive fiberglass cloth form, as I want to make comedic short films with these, and summer days aren't very friendly to guys in heavy, thick armor, as upposed to equally strong armor that is a lot less barbaric to my actors and I. Any comments/advice?

  10. #485
    Super nice tutorials, good sir! I just recently did my first Mark VI helmet and used fiberglass cloth on the inside. I've heard of the rondo method before, but this is the first time I've actually seen how it is applied. It looks so much easier (and less messy) than fiberglassing the inside like I did. I'm definitely going to try this on my next build. Thanks for the awesome step-by-step process!

  11. #486
    Great thread Ben!
    It shows that a lot of care and pride goes into your work. Just wanna say thanks for sharing this info.

    Cheers,
    Dave.

  12. #487
    Thank you so much for all this information. I was looking for something specific so I stopped by, and your thread answered and/or gave me what I needed to know for my own helmet project i'm working on. Thanks alot! =D

  13. #488
    First let me say great tut and incredible work. I am getting ready to rondo my first helmet and am keeping it stock so as not to overwhelm myself to start. I know this is completely off topic but I figured you are knowledgable enough to help me out, and for some reason I can't start a new thread. Have you ever thought about scaling a helmet to have it fit over a motorcycle helmet? I was thinking of taking an open faced helmet and building the helmet around it. Possibly 2 piecing the helmet and then combining them on/around the helmet. My concerns are that I don't want to look like a bobblehead. I am afraid that I would have to scale up so much that it would look rediculous. Do you think it would be a possibility of should I do like the other people on youtube and buy a haloween mask and cut and glue it. Also screwing into ot breaking the shell of the helmet renders it useless in the eyes of the DOT and the guys with the whirley red and blue lights. Thanks for your input and opinion.

  14. #489
    Thank you very much for the tutorial. Now I'll know what materials I'll need for my own projects. Keep up the good work.

  15. #490
    Quote Originally Posted by Shunhades View Post
    Thank you so much for all this information. I was looking for something specific so I stopped by, and your thread answered and/or gave me what I needed to know for my own helmet project i'm working on. Thanks alot! =D
    sadly I'm pretty sure you would end up looking like a bobble head. Scaling a helmet up to fit around a motorcycle helmet would be huge, not to mention the lack of peripheral vision you have while wearing one of these. If you still want to try it I would suggest the Halo 3 EVA. It's already pretty big so maybe it would fit around without having to scale it up to much. Also you would be able to make a custom visor that is large enough to accommodate the peripheral vision required to safely operate a motorcycle. That being said I fully implore you not to wear one of these while operating any motor vehicle. I have a motorcycle license as well as operating one and I wouldn't take the chance. It's already bad enough that other people have a hard time seeing you on the road, you need to be able to see them.

  16. #491
    Hey Ben, fantastic tutorials to say the least, just wanted to say thanks for helping the noobs and vets alike, I myself learned most of what I know from you. The vids are helpful, light-hearted, funny, and a blast to watch. I've actually watched them all a few times now, lol. I'm not sure if you remember me, I had taken a break from the 405th, but when I was here I worked in clay/foam mostly, but as someone who's actually finally going for a pep suit, I'm curious as to when you would sand at different grits, I haven't seen it covered in your vids, and I haven't ever went past about 180. I do understand that 2000+ or so, would be for an insanely glossy look, but not sure if 320 or so is desired/the norm. I'm also looking for "When" you would progress up in grits, after the bondo is sanded flat/smooth? Thanks for the reply in advance, and keep up the vids when you're not too busy at the store.

    -Jason

  17. #492
    Greatly appreciated.

  18. #493
    god i need to strecth my legs. i finally read this thread front to back and watched every vid. the way ive been doing it isnt a bad way but your way saves me soooooo many hours thats its not even funny. thanks alot for all this information

  19. #494
    this is the best tut i've found on the 405th as of yet to do with resin and rondo and bondo. it answered all of my questions and gave me great tips on anything else i was thinking of doing. this should definitely be stickied in the noob forum. Now I can actually finish my MK VI.

  20. #495

    Nice work

    this vid has helmed me alot thanks

  21. #496
    Thanks these vids have helped me so much, thanks.

  22. #497
    your Vids are grate hows the store going?

  23. #498
    Wow! Just finished going through all 50 pages. This tut is awesome and has answered so many questions for when I start my project soon, thanks Ben! How did the Reach helmet that started this post turn out?

  24. #499
    this will help

  25. #500
    Quote Originally Posted by BenStreeper View Post
    A brief break: How to Vac form an odst visor.







    Superwife deserves the credit for this amazing vac-formed visor. P.S. as of right now these are not cheap to make so if you want one you are better off (cheaper) buying from Sean or Link. This grade of petg sheeting is $18 a sheet, and right now it yields 1 visor
    Thanks Ben great tutorial. Was looking for a way to make my own vacuform visor.

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