The helmet is built . . . now what?

  1. #1

    The helmet is built . . . now what?

    I've got my helmet done . . . ears are in the mail (sorry no pics, I'm in the process of moving and the camera is packed up.)

    The helmet is cardboard with a skateboard helmet for the dome so my question is what now?

    Do I just go ahead and start bondo'ing what I've got or do I fiberglass it and then bondo or should I be trying to make a mold out of it so I can cast a helmet in resin?

    I've read a lot of the custom bucket builds on here but can someone give me some guidance?

    Thanks.

  2. #2
    Jaiden's Avatar
    Member Since
    Apr 2005
    From
    Titusville, FL
    Posts
    578

    Re: The helmet is built . . . now what?

    When you get settled in to your new place, take some pics and post them. It's hard to know what advice to give if we don't know exactly where you are in your progress. After the pics are up, we'd be more than happy to help.

    Good luck on the move!

    David.

  3. #3

    Re: The helmet is built . . . now what?

    Alright well, I'm in, my cable is installed . . . but I'm also getting married this saturday so I'll get the pics up AS SOON as I possibly can

  4. #4

    Re: The helmet is built . . . now what?

    Please dont rush the wedding just so you can get pics up, there are folks here all the time that can help congrats on getting married!!

  5. #5

    Re: The helmet is built . . . now what?

    Congrats on getting married. When you can get pics up that will help with being able to suggest what next. In the meantime, I can offer a little input. You shouldn't need to make a mold if you construct your helmet to be wearable as is. The skater helmet will allow for that, and as long as the rest of the construction is solid all should be good. The only real reason to make a mold otherwise is if you want to make multiple copies for any reason... like if you want to do different versions, like I do.

  6. #6

    Re: The helmet is built . . . now what?

    Thanks for the tips gypsy boy and no worries about rushing the wedding! However, picks will be up tonight, late tonight.

  7. #7

    Re: The helmet is built . . . now what?

    Ok . . . so late last night . . . early this morning, what's the difference?

    Anyways, here are the pics (Sorry about the quality but you get the gist. Also, it seems to not be symmetrical in the head on pic. . . that's not the case.):








  8. #8
    samlynn79's Avatar
    Member Since
    Nov 2007
    From
    Twentynine Palms, CA
    Posts
    240

    Re: The helmet is built . . . now what?

    Wow, that looks really good, man. It fits perfectly, and the shape is amazing. As for "now what", that choice is really up to you. You can focus on filling in the cutouts in the dome, using either bondo or fiberglass - personally, I'd use fiberglass - or you could incorporate the holes in the dome into a custom helmet design.
    If you chose to fill in the holes, my advice would me to do it from the inside with fiberglass first, then from the outside to finish it off.

  9. #9

    Re: The helmet is built . . . now what?

    What about for the helmet as a whole? Once I have the dome holes filled . . . do I fiberglass the helmet or just bondo it?

  10. #10
    SaxeCoburg's Avatar
    Member Since
    Oct 2004
    From
    Knoxville Tenn.
    Posts
    863

    Re: The helmet is built . . . now what?

    Papa John's Pizza! Heck yeah!

  11. #11

    Member Since
    Oct 2007
    From
    East Alabama
    Posts
    43

    Re: The helmet is built . . . now what?

    You could also just use bondo to fill the holes. Just put some duct tape on the inside to block up the holes. And then apply the bondo to the outside, filling it in in small increments. For holes, I would maybe use 2 applications. Bondo a light layer, let dry. Then apply again filling it in. Then sand it down. The first application will give a little bit more solid surface to apply the second coat too. Not a necessity, but could helmet.

    I don't have experiance with fiberglassing, and I've only worked on small projects with bondo. I would say use fiberglass to strengthen the helmet and then use bondo to give it its shape and form. Jaiden did it with his and the process looks pretty straight forward.

  12. #12
    samlynn79's Avatar
    Member Since
    Nov 2007
    From
    Twentynine Palms, CA
    Posts
    240

    Re: The helmet is built . . . now what?

    For holes like that, fiberglassing would be much easier. Put the layer of tape on the outside, and fill with a thin layer on the inside. Sand it smooth, and remove the tape, and smooth over the outside with another layer.
    For the rest of the helmet, I would use a very thin layer of bondo. It will make the entire surface extremely smooth. By very thin layer, I mean scrape it along the surface so it fills the pits in the cardboard, not actually put down a whole layer. Sand it with 320 or higher to make it smooth as glass.

  13. #13

    Re: The helmet is built . . . now what?

    Is the bondo going to dry brittle to the point where it will crack with flexing or will it dry hard enough that there just won't be flexing?

  14. #14
    samlynn79's Avatar
    Member Since
    Nov 2007
    From
    Twentynine Palms, CA
    Posts
    240

    Re: The helmet is built . . . now what?

    Putting on a layer thin enough to fill the pits in the cardboard won't crack at all. Now if you want to take the flex out of the helmet, I would suggest putting a layer of fiberglass, which is harder and resists cracking alot more, on the inside of the helmet.

  15. #15

    Re: The helmet is built . . . now what?

    Well I keep going back and forth between these and my guns . . . but I'm leaving for my honeymoon today. However, when I get back, the bucket is first in priority of work. Thanks for the help.

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