Aluminum Helemt Casting Process -A real Hand-Schaub!

Whew, damn is that an amazing looking helmet! Lots of hard work must have went through that, & just to make 1 helmet - but I think it was well worth every second, looks great!
 
That has to be the coolest thing I have seen here so far. Sweet! That's pretty hardcore and very interesting. I never knew how you do that. The pictures are great too, thanks.
 
:eek: :love (speechless, my voice amplifier system is damaged due to the beauty of this work...incredible and awesome! :D(y)

Robert
 
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Is it bendable metal or can you actually travel back in time and slay king arthur with it? :p

great work man, I wonder what it weighs aswell and if there is anyway you could start a line-up for these buckets and make some more fett fans wear REAL armor.
 
Well I have no clue what kind of aluminum was used but I have a Medieval gorget that is aluminum plate, and its made from aircraft aluminum, 5 times harder than regular steel.
 
Casting your own aluminium helmet isn't that hard anymore, can I draw your attention to "Lost Foam Casting".
You sculpt the helmet from polystyrene foam and pack it in casting sand, liquid aluminium is poured into the top, it melts the foam but not the sand leaving you a very good representation of the foam part.
 
Evilution said:
Casting your own aluminium helmet isn't that hard anymore, can I draw your attention to "Lost Foam Casting".
You sculpt the helmet from polystyrene foam and pack it in casting sand, liquid aluminium is poured into the top, it melts the foam but not the sand leaving you a very good representation of the foam part.
Click to expand...



AAAAAHHHHHHHHHHHHH yeah , not hard,,,,,uuuummmmmmmm,,, yeah. goes just like that
 
Hmmm - interesting - I didn't think this thread ever got attention anymore.
Evilution - Your process sounds similar to the lost wax sand casting but what is shown above is not the same. It would be difficult to make multiples if you were sculpting each foam piece beforehand.

Anyway, the aluminum is virgin aluminum so it doesn't have the strength as traditional medieval armor. Although I suppose it would do all right in a dragon battle. It weighs around 5 lbs and oddly enough it is quite comfortable if padded correctly.

And while we are on the subject... Here is my favorite shot of my all aluminum Fet and Stainless steel ride...

Jangodmc2.jpg

All armor elements are aluminum (cast and formed) and the helmet is my own sculpt and cst using the same method as above.
 
If you're going to make a time machine you might as well make one with some style!!


Awesome suit Brian,and an equally cool car :cheers

Steve
 
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