N7 cardboard helmet

Khol · Aug 18, 2013

Hi guys! Here's my first test at an inspired N7 helmet!
First was the file I got from Cipher_t13! Thanks
Used pepakura to unfold and used cardboard box cutting the pattern out of it!

I then use bondo to seal the sides of cardboard.

Doing sending now and will update with more in couple days

--Khol--

Leonidas1 · Aug 19, 2013

looks really good keep it uo

edwardjlw · Aug 19, 2013

Another cardboard builder, this looks great. Are you planning to do the rest of the armour, or just the helmet?

Either way, you're doing great so far keep it up

Khol · Aug 19, 2013

edwardjlw said:
Another cardboard builder, this looks great. Are you planning to do the rest of the armour, or just the helmet?

Either way, you're doing great so far keep it up

Not sure yet for the armor... Been working on inferno armor and did some unfolding for couple days now!
Did foam last year but lost about 40pounds between the start and end lol it was too big for me lol

Khol · Aug 21, 2013

Little update!
Seen many questions in the forums and want to share how I'm filling the gap cardboard leave...
Using small Popsicle sticks to fill the sides of cardboard:

And I'm using dremel tool to sand bondo :

Here's the update on my helmet:
Been sanding like crazy the past 2-3 days still have top to send but almost done!

Still not ready for paint but looking good so far

Also little question if anyone can help:
What can I use for the smaller corner to sand (back of helmet where round edges meet the sides)?!

Mangos · Aug 21, 2013

I would cut/tear a small piece of sandpaper off of the sheet and roll it up into a small tube (about the size of a small drill bit) and use that to sand. You could also wrap the sandpaper around a small straw, toothpick, drill bit or anything that would fit into the space that you need. I hope that helps.

Khol · Aug 21, 2013

Mangos said:
I would cut/tear a small piece of sandpaper off of the sheet and roll it up into a small tube (about the size of a small drill bit) and use that to sand. You could also wrap the sandpaper around a small straw, toothpick, drill bit or anything that would fit into the space that you need. I hope that helps.

Thanks! It did help a lot

Khol · Aug 23, 2013

Update for helmet:
Finish first sanding on top!

And I just realize the sanding bit I'm using with my dremel was 120 not 60 lol that's why it was sooo looong!
Here's some questions!
Can I use primer to see better the places to get smoother and add bondo?
Also my helmet don't feel that solid! I didn't put any rondo/resine inside (since I used cardboard I was under the impression that would be solid enough!) can I add at least resine inside to keep it from cracking?

kadet · Aug 23, 2013

Khol said:
Update for helmet:
Finish first sanding on top!

And I just realize the sanding bit I'm using with my dremel was 120 not 60 lol that's why it was sooo looong!
Here's some questions!
Can I use primer to see better the places to get smoother and add bondo?
Also my helmet don't feel that solid! I didn't put any rondo/resine inside (since I used cardboard I was under the impression that would be solid enough!) can I add at least resine inside to keep it from cracking?

Yes primer is a good way to see what places need more perfection. The outside of your helmet does look solid enough for an inside coating of Rondo/resin.

Khol · Aug 23, 2013

kadet said:
Yes primer is a good way to see what places need more perfection. The outside of your helmet does look solid enough for an inside coating of Rondo/resin.

Thanks! Will have to do resine inside... Some parts had to be hot glued again...
Just don't want it to warp with the bondo outside lol

Khol · Aug 23, 2013

Primer coat on, getting ready for last touch up of bondo!
Front

Back

Side

Can't wait to get to paint lol
Still have to do holes to breath lol

Mangos · Aug 24, 2013

I'm glad I could help. It's looking really good, mate.

Khol · Aug 29, 2013

Little update!

More bondo and sanding with 220 grit

Still work to do with bondo and sanding but happy with my first helmet progress so far

Khol · Aug 30, 2013

Didn't like the way it tuned out after sanding, this time I use sand paper with wood pieces underneath!
Looks a lot smother then using my hands lol

firefighter72 · Aug 30, 2013

man that looks really good. what did you use 2 harden it because ive seen that used before but cant find out what its called i call find the bondo/fiberglas methods all over the place but thats it

Khol · Aug 30, 2013

firefighter72 said:
man that looks really good. what did you use 2 harden it because ive seen that used before but cant find out what its called i call find the bondo/fiberglas methods all over the place but thats it

Here's what I use:

Resin (first one) can be use alone or with fiberglas mat (2e)
Body filler (3rd one -> also called "Bondo") can be use alone or with resin (called "Rondo")

For mine I used only resin and bondo!
You have 1 hardener with the resin and one for the bondo as it comes with the container

-Khol-

Motion26 · Aug 31, 2013

kadet said:
Yes primer is a good way to see what places need more perfection. The outside of your helmet does look solid enough for an inside coating of Rondo/resin.

Yep, that's what I've been doing as well, the bondo puddy I have is red and the helmets grey/white - so every once and a while i do a coat of primer to see where exactly I am at for the over all shape. This looks pretty awesome, its cool to see people going with cardboard every once and a while

fiercesteam · Aug 31, 2013

doesnt look like you have fiber glass in there. The build later on could get difficult without it, and the bondo could crack. you should add at least a layer inside the helmet

other than that, the helmet looks great!

Khol · Aug 31, 2013

Motion26 said:
Yep, that's what I've been doing as well, the bondo puddy I have is red and the helmets grey/white - so every once and a while i do a coat of primer to see where exactly I am at for the over all shape. This looks pretty awesome, its cool to see people going with cardboard every once and a while

Thanks

can't wait to paint but want to get it really smooth!

Khol · Aug 31, 2013

fiercesteam said:
doesnt look like you have fiber glass in there. The build later on could get difficult without it, and the bondo could crack. you should add at least a layer inside the helmet

other than that, the helmet looks great!

Thanks!
Since I use cardboard pretty thick, I didnt use Fiberglas inside.
I did use resin inside and outside, so far it's good!

N7 cardboard helmet

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