Helmet
I was running out of time by the time I got to the helmet so there are a few flaws that could
have been avoided but it still turned out good enough for Halloween.
I found for a PEP that's enclosed like the helmet instead of using the supports I make it hollow
and put one coat of resin on the outside then check the shape and geometry and make
adjustments then do a coat on the inside and, if everything still looks good, do one more
coat inside and out. That leaves you with a shell that will hold it's shape when you rondo
or fiberglass.
I found a small dremel cutting bit that works good for thin cuts.
The inside of the helmet has a thin layer of rondo for backing to sand into then fiberglass
mat in areas that need extra strength and fiberglass cloth over everything for strength
and smoothness and finally a very thin mix of rondo for more smoothness.
Even with all the layers the helmet is just over a pound finished.
The vents are wire loom I heated up and stretched on some pipe then cut to fit.
For the detail parts I used cardboard paint canvas. It's just thin layers of paper that
can be flexed and bent into the shape you need to wrap around and it paints very well
and usually comes in thickness of 1/16 to 1/8.
The visor uses two motorcycle helmet shields from Ebay, if you search for HJ-11 or
CL-33 visor it should pop up.
The back main visor I covered with tape and put inside the helmet to trace out the opening
leaving the tape on until the end to protect it.
For the front detail visor I made a template by sticking a piece of cardstock inside the helmet
with the back visor backing it to trace out the opening then after cutting and fitting to the
opening over the back visor I figured out the shape and finished cutting out the template.
After cutting the front detail visor I cleaned up the edges with a small drum sander on the
dremel and used a mouse sander to flatten the lines. Then a black permanent marker to
blend the edges.
The scale size I used is just big enough to fit around the ears and has room inside for
some thin padding.
**update**
I ended up just using some foam pipe wrap as padding, it just fits inside the shape of the helmet
and I didn't even need to glue anything, this way down the road I can put some real padding
inside and the old stuff will come out easy.
I was running out of time by the time I got to the helmet so there are a few flaws that could
have been avoided but it still turned out good enough for Halloween.
I found for a PEP that's enclosed like the helmet instead of using the supports I make it hollow
and put one coat of resin on the outside then check the shape and geometry and make
adjustments then do a coat on the inside and, if everything still looks good, do one more
coat inside and out. That leaves you with a shell that will hold it's shape when you rondo
or fiberglass.
I found a small dremel cutting bit that works good for thin cuts.
The inside of the helmet has a thin layer of rondo for backing to sand into then fiberglass
mat in areas that need extra strength and fiberglass cloth over everything for strength
and smoothness and finally a very thin mix of rondo for more smoothness.
Even with all the layers the helmet is just over a pound finished.
The vents are wire loom I heated up and stretched on some pipe then cut to fit.
For the detail parts I used cardboard paint canvas. It's just thin layers of paper that
can be flexed and bent into the shape you need to wrap around and it paints very well
and usually comes in thickness of 1/16 to 1/8.
The visor uses two motorcycle helmet shields from Ebay, if you search for HJ-11 or
CL-33 visor it should pop up.
The back main visor I covered with tape and put inside the helmet to trace out the opening
leaving the tape on until the end to protect it.
For the front detail visor I made a template by sticking a piece of cardstock inside the helmet
with the back visor backing it to trace out the opening then after cutting and fitting to the
opening over the back visor I figured out the shape and finished cutting out the template.
After cutting the front detail visor I cleaned up the edges with a small drum sander on the
dremel and used a mouse sander to flatten the lines. Then a black permanent marker to
blend the edges.
The scale size I used is just big enough to fit around the ears and has room inside for
some thin padding.
**update**
I ended up just using some foam pipe wrap as padding, it just fits inside the shape of the helmet
and I didn't even need to glue anything, this way down the road I can put some real padding
inside and the old stuff will come out easy.
