My First Master Chief Helmet

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parabus

New Member
I have been looking all over this site for about a month now, I was considering buying some armor, but it is just out of my price range. I decided to make my own Pepakura helmet below are some pictures of my progress so far. I think that this site is a great asset to every halo fan, and I think the armor being made by the members here is awesome.

Here are Pics of the completed Pepakura Helmet.
Picture354.jpg

http://i216.photobucket.com/albums/cc118/p.../Picture353.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture354.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture361.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture363.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture364.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture365.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture366.jpg

I used 110lb cardstock, and read all of the how-to tutorials for Pepakura. I get compulsive once I start a project like this, so I worked for about 6 hour’s straight to put the helmet together.

Here are Pics of the helmet about 15 minutes after I applied my first coat of resin. I almost didn't put the visor in before starting, but then I changed my mind because I thought it would add more support.
Picture367.jpg

http://i216.photobucket.com/albums/cc118/p.../Picture368.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture369.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture370.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture371.jpg
http://i216.photobucket.com/albums/cc118/p.../Picture372.jpg

I do have some questions, and would really appreciate some advice.

When I start to fiberglass the inside of the helmet, how small should I make the strips of fiberglass? Can I use large pieces to cover most of the inside, or are small strips the best?

Should I only fiberglass sections of the helmet's interior, or should I do the whole thing at once?

What is the best way to create detail on the outside of the helmet? Should I apply multiple coats of resin to the outside, and then sand them, or should I use the bondo body filler that I have been reading about? I am not sure how thick to make the helmet, and do not want to make it to bulky, but I do want to create more detail than the Pepakura model shows.

I know that I am going to cut out the cardstock visor and use a dual motorcycle visor, but I would like to know how to secure the visor to the helmet.

I know that I have a lot of questions, but I just want to do this right.
 

MandoMan531

Member
Hey, im pretty new to this too. i have a post on this same page showing my progress. your helmet looks great, just like mine. the cardstock and scoring the lines does wonders.

When i fiberglassed the inside i used biger pieces where i could. like right in the top of the helmet i used as big of a piece as i could. Around the sides you have to use smalled pieces. my second layer was all medium sized pieces. overlapped. then i used my angle grinder to get some high spots off the inside and went over it all with a thin coat of fiber reinforced filler to get a more smooth shape.

Your probably going to want to do the inside in sections so you can avoid warping the helmet. i set my helmet upside down and did the iside top. then one side, then the other, then the front chin area and then the back. the second layer youcan do all at once because the helmet should be good structuarally. make sure you keep test fitting it when its dry to make sure you have room for padding.

for detail im doing a few coats of resin and then sanding. then ill primer it and see where it stands surface-wise. use different fillers where needed and keep sanding.

youcan also add detail using sheet styrene/Sintra/hobby plastic in different thicknesses. vents andtubes an be backed with different kinds of mesh/wire loom etc.

for the visor ive devised a plan to install small pins in the helmet the visor can slide onto, then itll be sealed with silicone and the pins secured with glue or epoxy.

my advice is get workin onthe fiberglass and concentrate on getting it structurally sound and stay tuned to my thread. inthe next week or so i should have some nice updates. searching never hurts either.
 

Agent Orange

Jr Member
parabus said:
I have been looking all over this site for about a month now, I was considering buying some armor, but it is just out of my price range. I decided to make my own Pepakura helmet below are some pictures of my progress so far. I think that this site is a great asset to every halo fan, and I think the armor being made by the members here is awesome.
Looks great, i believe mando summed up your questions. KEEP TRUCKING! 13 days left!
 
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bikelomen

New Member
Its really easy to get a can of spray adhesive and coat the inside of your helm really well. Then cut different pieces of MAt or cloth and stick them in your helmet. The spray adhesive holds it in place and allows you to form it to all the curves and get the cloth or mat to lay down. Place your helm upside down then coat the cloth or mat with resin. This is after you have a few light coats of just resin on the outside of the helm to hold the shape of the helm. You wont believe what this small step of the adhesive will do in making your life a lot easier. The adhesive can be the cheepest you can find ( The one I use is $3 a can). Just needs to hold the weight of the cloth untill resin hits it. Try to do small sections at a time like the top, then the right side, then the left and so on. The resin should fire off rather quickly so it will not take that long to mix and apply mix and apply. Make sure when you are applying you are pressing the air out of the cloth with your brush. Good luck.
 
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