HELLJUMPER'S DOT Approved MkVI Motorcycle Helmet Build (pic heavy)

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swampbilly

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Hey yall just wanted to post my DOT approved motorcycle helmet build based off the low res MkVI pep helmet. It took me a total of 6 months to complete despite being my 5th helmet i still learned alot from this project. The whole idea was to be safe on the road but look like a bad ass lol. Plus it matches the My motorcycle build found here: http://www.405th.com/showthread.php/41628-HELLJUMPER-S-Masterchief-Motorcycle-Build-(pic-heavy)

I started out with this speed and strength helmet at a cost of $80. As i purchased the helmet i had brought in my pep helmet to aid in the purchase and to get all the guys in the bike shop excited. (they were)
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I disassembled the new helmet and removed all the inner padding and epdm foam. and began sanding the out side to rough up the surface to allow a good hold for the fiberglass resin that i was expecting on using.
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After that i began applying the resin first coat to my pep helmet.
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Once my pep helmet had been resined, i cut it into sections expecting to "graft" it onto the helmet using fiberglass cloth and resin.
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I then used a can of spray foam (the least expanding) and foamed in all the air pockets and space created between the dot helmet and the fiberglassed pep pieces.
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Once the foam was dry and completly done expanding, I trimmed the excess and began overlapping fiberglass cloth over and around the areas i had cut and where it needed to be strongly attached to the helmet.
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Then some bondo as i went along spraying primer to see the imperfections.
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NOW AS YOU ALL MIGHT HAVE NOTICED....THERE WERE NOTICED BY MYSELF SEVERAL ISSUES....IT WAS HUGE! IT WAS UNPROPORTIONATE! IT WAS TO BE HONEST......RUSHED.....RIP IT OFF! LETS MAKE IT BETTER.....AND BADDER...
I decided to build a new pep helmet.....into the dot helmet. taking into consideration the helmet is ALREADY round. Notice i said INTO the helmet instead of ONTO the helmet.....that was my first mistake.
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Now its time to glass this beautiful much more eye appealing helmet.
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Bondo process. Smoothing out edges and fixing voids. Missing some photos.
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At the last few weeks i realized that i wanted more detail and begain making some pretty deep cuts into the helmet and making some modifications. as you can see the "ear slot" in the side was cut out longer. And there isnt a picture but i cut into the back of the helmet a long step down which you will see in later pics.
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Paint and some detail foam.
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Some test fitting.
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AND THE ALMOST FINISHED PRODUCT.
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Thank you sir. Its not perfect I know that but it IS on a premade helmet so I wasnt expecting it to be. :)
 
This is beauitiful. IF I ever rode a motorcycle I would die of happiness to wear something like this.
 
New plan for bike! Bought this. Going to paint all armor peices to match bike and helmet. Daily drive in style. What do yall think?Screenshot_2014-07-23-18-24-45.pngScreenshot_2014-07-23-18-24-40.pngScreenshot_2014-07-23-18-24-49.png
 
Looks great! but...

How did you fit the visor once the whole thing was made? From the first pictures it looked like the visor wrapped around to the ears and then screwed in to the helmet?
 
I like it. Don't ride myself but that would be rather neat to see go zooming buy.
 
Looks great! but...

How did you fit the visor once the whole thing was made? From the first pictures it looked like the visor wrapped around to the ears and then screwed in to the helmet?
The first attempt I was planning on clipping it around the outside of the helmet but I never made it that far before I ripped the outer shell off and continued with a new build. The second and currently final attempt I completly built the pep glass and bondo of the helmet and then fit the visor on the inside. I positioned the visor behind the opening and using a paint marker marked off the path of my cut to allow proper fit. Inside near the cheek/ear area there was a raised cylindrical ridge keeping the visor from sitting flush. I simply drilled a hole where those were. Now the visor could be flexed, inserted into helmet and unflexed as the cylinder keyed into the holes in the tips of the visor, essentially snapping into place. With a 1/4" overlap around the opening the visor cant slip up or down and allow air through. With the EPDM foam peices and soft padding installed it furthermore holds the visor in place on all sides.
 
I like it. Don't ride myself but that would be rather neat to see go zooming buy.
Yes thats the idea. Since i finished the helmet ive been in more photoshoots at traffic lights and gas stations then I imagined. From parents taking pictures for there kids to little kids bravely approaching me to tell me how excited they were to "dude that is awesome". The idea of the armor is for safety protection and add just a little more to the ensemble. Id hate to have to armor up with chief armor everday for work lmao
 
Sucks that you had to rip off parts and "start over" due to it be unproportional. End result looks great thought! And the fact that it is made on an existing helmet ought to give it a stronger base. Just don't get into any accidents now...for the sake of not breaking the helmet, and of course your health haha. Good stuff man.
 
Sucks that you had to rip off parts and "start over" due to it be unproportional. End result looks great thought! And the fact that it is made on an existing helmet ought to give it a stronger base. Just don't get into any accidents now...for the sake of not breaking the helmet, and of course your health haha. Good stuff man.
Lmao its funny you say that because that is EXACTLY what I said to my wife. goodbye honey be safe....of course. I got a helmet to protect.
 
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