Last night I got the fiberglass resin on the outside, but due to the cold temperatures it took until about noon today to finish curing. Some really rough spots on the outside of the helmet due to the cold temps, but nothing that bondo and sanding wont fix. This afternoon I used a casting resin called armilite (only thing they had locally) to cast the inside of the helmet instead of doing fiberglass. So far I am happy with how it turned out. The Plastic working time is short(I think the box said 90 seconds?) making it difficult to cover the entire inside of the helmet. I ordered smooth cast 300 though to make cast after the mold process, and expect better results from it.
So everything is going good, and somewhat on schedule. The only concern I have is wether or not I have enough plastic enroute. The armilite was 28 oz and I have already used half, and I only have the smooth cast 300 trail size in the mail. How many oz of plastic does it normally take to cast a helmet without any flex?
More pictures soon and I hope to take a video of the silicone mold process. I'll keep you posted!