Howdy, it's Blogerella, Loess' fiance and the soon-to-be wearer of this costume! Loess finally got me chased onto the computer to make my first substantial post.
We got a little bit done on the Big Sister helmet this weekend, and you can see that it's finally starting to look like the actual helmet. We first laid out all of the greeblies and taped them to the helmet for placement, traced around them, and cut out all the openings.


We also modified the greeblies themselves to better match the concept art. All of the small ports are basically PVC pipe fittings, so we had to drill out the ends with hole saws, and sand off some of the outside bumps with a Dremel. Sorry that we don't have photos of the items during production--ALL of my camera batteries happened to be dead that day! We also cut out the Lexan windows for the small portholes--they have masking tape on them, so that we could trace the circles without harming the Lexan:
Here are several views of the helmet with all of the greeblies taped on:
This project has been a big lesson in Reusing and Recycling! The largest of the small portholes, which is located at about 1 o'clock on the helmet when facing the front, sits on a donut-shaped piece of fiberglass; this piece is supposed to be a flange of sorts. This circular piece was actually the piece we cut out of the main porthole that we shaped up and attached wooden spacers underneath. We're also going to use the ends of the PVC pipe-caps that we sawed out of the little portholes to make various caps and plate covers, as needed.
NEXT UP: Epoxy all the helmet greeblies on, and apply bondo glass where needed to simulate welds. We will also be applying the last layer of fiberglass on the air tank to hold the foam endcaps on more securely. This weekend, we're making a Tandy Leather run to pick up about a dozen more buckles, and the leather for the corset and hot pants. Now I have to teach myself how to sew leather!