Foam helmet Experiment

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Zero 071

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So I tried an experiment...
I wanted to see if I could have the comfort and forgiveness of foam, with the rigidity and detail of resin. Plus I needed a new, more accurate bucket. Here's my progress:


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I made the first one (gray) way to big, so I rescaled and put a little more effort into the details

heres a side shot of the new one made from 5mm craft foam

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and a front shot during construction

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basic construction nearly complete

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first coat of epoxy resin (XTC-3D from smooth on)

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and several more coats

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some sanding to see how the cold cast powder worked out (great except all for not when paint came)
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spot putty to help fill some voids and smooth it all out
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a coat of plastidip
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base coat of silver
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I put another coat of darker gunmetal color on but didnt get pictures, sorry, but this is when I taped off the pattern I wanted
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tape removal and pattern reveal
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removal of masking latex for weathering
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front close up
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removed tape from visor and etched my shark teeth in (I cant resist, I did this on my old helmet and loved it)
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some added weathering (used a nail file with a drop of paint spread around in it)
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What do you guys think?
 

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It looks very cool man :)
Is there a way you can make the details stand out more with the finished paint job (of which looks rad)?
 
Most likely, its actually not quite done. I have a few details yo add and vinyl decals for lettering and such
 
Looking pretty spiffy there buddy. :)
so was the 5mm stuff pretty easy to work with?? i was thinking about going with that size when i do a helmet.
 
Looks great! How rigid is it? How heavy is it? I am really impressed with this!

Pretty rigid, at least the parts that are epoxy'd, not much heavier than a normal foam bucks, so pretty light.



Looking pretty spiffy there buddy. :)
so was the 5mm stuff pretty easy to work with?? i was thinking about going with that size when i do a helmet.

Very easy, its my go to foam for buckets and most detail work that need a little strength or more substance than 2mm. I love working with the stuff.

BTW



I know they are long, but these are a couple videos i made of making helmets
 
Last edited by a moderator:
Very easy, its my go to foam for buckets and most detail work that need a little strength or more substance than 2mm. I love working with the stuff.

Righteous, thanks for letting me know, and i like the videos so far :)
 
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