Hey everyone, I have been working on an ODST armor for some time and I am getting close. Anyway, I have started making the visor for the helmet and I noticed that others have been having difficulties so I am posting my current process and how it works.
I am using plastic called acetate, it is available at art stores and also online (just google search it) its pretty cheap. The pieces I am using for this tutorial are clouded, one because i don't want to waist my clear stuff while figuring out the fit and two because it will make it easier to show what I am doing in pictures.
Step 1. Get Pep File pattern
First you need the Pep File that has the Visor pattern. I am using the Rookie helm made by Rundown and unfolded by RalPartha, you can get it from the link below:
Once you get it print just the page with the Visor pieces, and cut out the pieces for the top and bottom part of the visor
Cut the fold tabs off of each piece.
Step 2:Trace the pieces onto the plastic sheet
You can just flip the same top piece to get both sides, or you could cut both out, but i didn't see the point.
The Bottom piece should be traced onto the sheet so that the two top edges are connected to the top piece.
Then sketch out a line about a 1/4" away from all of the outside edge as shown. This will give you room to attach your visor to your helmet. Also put two black dots at the top and the bottom 1 inch away from the center line of the piece as shown.
Step 3: Cut out the piece
Cut along the dotted line you sketched, be sure to have a new sharp blade or it will be much harder. Be careful as the blade may catch in the plastic, if it does back it out and start the cut back over, don't force it, or you will risk scoring your piece in places you don't want to or even cutting yourself.
This what mine looked like when it was cut out. I was cutting from a roll so it naturally bends the way I want it. If you are cutting from a flat sheet don't worry, it will be pliable enough to form to the helmet.
Step 4: Score the piece
After the piece is cut, lay it flat on the cutting board and place a ruler so that it gives you a straight edge from the dots you made earlier.
Carefully move the blade down the line. Do not use a lot of pressure. I mean, use as little as you can while still pressing against the plastic. You may have to run over it a couple of times, but you do not want to cut through the plastic all the way. Also score a line in the same manner across where the top and bottom pieces meet. Once scored, place your thumbs on either side of the score mark and bend the piece to create the crease in that spot. It should take a little force and should also stay pretty much where you put once it is bent. Do NOT bend it back and forth, this will cause it to break eventually.
When it is done it should look like this:
Step 5: Apply VHT Nite-Shades
The trick I found with this stuff was to spray it at a moderate pace across the piece about 4-5 inches away. Don't go back and forth just one pass with a slight overlap since the part is going to be bigger than the width of the spray.
This is the part that I found to be very important. Count to 30 after you are done spraying the piece the first time. Then spray the second layer. Repeat again for the third layer and if you want it really dark go for a forth.
Here are the results.
And here are some more pics of it hot glued in and from the inside
Here are some pics with a light inside, this isn't a light kit or led, it is just a lamp, but it shows that with illumination behind the visor you can see through it. Meaning you can get the same effect as Sean's helmet.
Hope this helps everyone out and good luck!!!!!!!!!!!!!
Help my Project!!!