Pep Armour and Helmet - WIP

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iwantaxbox360

New Member
First a big thank you for the time taken by so many members to provide high quality tutorial and LOTS of picture advice.

My son and I are both big halo fans, and thought a costume for halloween would be in order. So to outline my lack of experience in this field...
1. Had no idea what pepakura was until i found this site
2. Never made any paper/card or any kind of model in my life
3. Artistic ability is zero to a negative 10
4. Painting ability - akin to a 1st grader i think.
5. Glue gun experience - 0%


So I am not actually a good candidate for this project what wanted to give it a go. I will put pics up today of the progress so far. With the help of these tutorials on this site, i think i have done OK so far. This has been a learning curve of epic proportions for me.

My biggest worry is the resin and fiberglass stage , I have never worked with resin of fibreglass before, so my biggest concern will be messing the whole suit up.
I am currently remaking the helmet as i have gotten better with this pepakura, so the new helmet should be ready today.

I think i have read every post in this forum now yest i spent a month reading everything before i started to even consider making it.

You can see the helmet needs to be re-done, which is happening today.
 

Walter Spase

Well-Known Member
YAR!!! someone that read... hey, you have any questions about fiberglassing and detailing, shoot me a PM.. I'd be glad to lend you my experience...
 

preskewl

Member
Same here.. If you need help let me know.. I actually gotta redo my calf.. It shrank during the fiberglass process.. I couldn't get my leg in there.. Cut it in half and still don't look right.. I guess, I'm back to paper folding and fiberglassing.. ;)
 

LastSpartan

Sr Member
This is a really nice job you did!

For the fiberglass, you just need to be patient or everything will end up with a big mess.

Follow the instructions, and your son will have his best HALOween!
 

Liamthedevastator

Well-Known Member
I agree with LastSpartan, as long as you take your time, you should be A-OKAY! Besides, considering you have never done this before it looks amazing! Kids these days are so lucky=]
 

iwantaxbox360

New Member
Thanks for the comments so far. i finished the 2nd attempt for the helmet today, so i am already to go with the resin tomorrow Gulp!.

I will take the advise and go slow on this part now.

I went and ordered the visor from the local bike shop (they want to see the finished costume now). BUt looking at one of the visor it looks like i will have to cut the side in order to fit it in the helmet, Is a dremel the only way to cut these visor's nice and clean?

Steve
 

iwantaxbox360

New Member
Sat here looking at detail pic's of MC for detailing I decided to work out what i had spent so far...this is not good[/b]

110lb card stock 2off $10
1 glue gun $5
Glue sticks $3
Exacto knife & cutting board $9
3 packet of blades $7
1 metal ruler $2
10 foam brushes $8
10 cheap bristle brushes $5
3 packets of fiberglass cloth $18
I Large tin of resin $44
3 cans of primmer $10
3 cans of test colours for the suit $10
1 can of silver paint $4
1 HJC visor $36
1 soldering gun $8
switch, batt compartment for fans $8
2 cpu fans $15 (delivered)
Paintball gloves $20
LED lights $15
undersuit $40
snaps for undersuit $3

A bank breaking, and scream of ...'I am not sure I love my son this much' ....$280 so far!

I still will need more spray cans of colour i am guessing another 5 or 6.

And then there is my time on top of that.
 

AoBfrost

Well-Known Member
Steve may just be the next pep armor god.

I'm working for around 100 dollars as my budget, if it goes over, thats ok, I have a job and will just not spend on anything for a while to make the cash back up. This did dent my vespa budget, but heck I'm not buying one till next spring/summer anyways.
 

preskewl

Member
Steve said:
Sat here looking at detail pic's of MC for detailing I decided to work out what i had spent so far...this is not good[/b]

110lb card stock 2off $10
1 glue gun $5
Glue sticks $3
Exacto knife & cutting board $9
3 packet of blades $7
1 metal ruler $2
10 foam brushes $8
10 cheap bristle brushes $5
3 packets of fiberglass cloth $18
I Large tin of resin $44
3 cans of primmer $10
3 cans of test colours for the suit $10
1 can of silver paint $4
1 HJC visor $36
1 soldering gun $8
switch, batt compartment for fans $8
2 cpu fans $15 (delivered)
Paintball gloves $20
LED lights $15
undersuit $40
snaps for undersuit $3

A bank breaking, and scream of ...'I am not sure I love my son this much' ....$280 so far!

I still will need more spray cans of colour i am guessing another 5 or 6.


And then there is my time on top of that.

I'm scared to even think how much I spent on my armor.. Well, I might as well calculate it too.. Especially for people that are trying to get into it.. (gulp)

Oh this does not include my SB Helmet I got a few month's ago.. :cautious:

(1) 200 sheets 110 lb card stock $12.00
(1) 6" Bone Folder $8.00
(3) Tacky glue $3.00
(4) resin pints $48.00
(4) fiberglass cloth $24.00
(1) 4.5 oz glazing putty (3.50)
(1) Bondo filler 1 gallon (18.00)
(2) 2 sanding block $10.00
(7) paint brushes ($8.00)
(5) Primer filler ($20.00)
(10) Paint ($70.00)
(1) Heat gun ($28.00)
(1) hand sander ($28.00)
(5) Sand paper ($15.00)
(1) flashlight ($5.00)
(1) pvc piping ($2.00)
(1) dremel grinding drums ($3.50)
(1) dremel cutting wheels ($7.00)
(1) fast orange hand cleaner (.80)
(1) Bondo round Cheese Grate ($4.00)
(1) paintball gloves ($11.00)

Total rounded $286.80 giver or take on tax

stuff already had around the house and work: freebies!
Glue Gun
Glue sticks
2 boxes of rubber gloves
extra sandpaper
dremel tool
putty knife
goggles
dust masks
cardboard boxes
foam boards
Flat cheese grate and holder
respirator


I still need the following:

undersuit
leds
wires
batteries
velcro and strapping
and possible other things that will come up..

Oh and let's not talk about time.. I have been working on this everyday after work for 3 weeks.. Starting at 7:00pm to 1:30 AM.. Weekends from 10 am to oh dark thirty.. for the past 3 weeks.. Deadline is on the 26th of this month ;)
 
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iwantaxbox360

New Member
AoBfrost said:
Steve may just be the next pep armor god.

I'm working for around 100 dollars as my budget, if it goes over, thats ok, I have a job and will just not spend on anything for a while to make the cash back up. This did dent my vespa budget, but heck I'm not buying one till next spring/summer anyways.


I think MUG might be a better description of me..lol

That really shocked me when i sat down and worked it all out......you watch it will look like crap when i finished it now!

Anyway I will be sticking the fiberglass cloth into the suit this afternoon, and will resin the fiberglass tonight/tomorrow.
 
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AoBfrost

Well-Known Member
4 cans or resin? This is a costume not US military bullet proof vest lol.

That thing will be 100% baseball bat proof when done I bet.
 

preskewl

Member
AoBfrost said:
4 cans or resin? This is a costume not US military bullet proof vest lol.

That thing will be 100% baseball bat proof when done I bet.


Ha ha.. Sounds like a lot but actually it's probably less then a gallon.. Since it's 4 pint cans.. I couldn't find the big gallon one up untill yesterday at another autosupply store.. I messed up and used fiberglass mat on my chest and back piece. That sucked up about 1pint... Costly mistake on my part, but well.. I learned alot.. Oh, and I also had to redo my left and right calf pieces.. Fixed cracking pieces and resin my AR. So it was more then enough.. I have like a 1/4 left of resin sitting there..
 
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iwantaxbox360

New Member
Preskewl,

Looks like we have the same deadline.

Thanks for you list...i have never heard of a bone folder...I wish i had used one of them when i was folding, but i will be buying one today...for the next project..lol

It looks like the $300 mark is pretty true for most pep armour if you do it all, paint, lights,fans etc.

Touch wood, so far i havn't had any problems with resin. I was struggling with keep the chest piece shaped for resin, but i found an old pillow worked great to keep its general shape so i can finish it.

Steve
 
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