Helmet Prep

Just cut out the visor and keyslots on another bucket last night. Its a fun part of the process. Just put a cutting wheel on your dremel and go to town. Stay steady and go slow, take breaks if you need to. Oh, and wear a dust mask. Have fun
 
Do the keyslots first. It helps to maintain the structural integrity of the helmet if you work the small areas first.
 
I tend to not cut right up to the edge when I use a power cutter. Leave just a little bit, which you can then clean up with sanding and stuff. I find if I try to cut it right up close I almost always have a boo-boo and cut into something I shouldn't have. On the other hand, don't worry too much if you do. That's what auto putty and fine-grit sanding are for.
 
Find the right size drill bit that will match the size of the slots but don't go out of the lines. It's better to use a smaller drill bit at least you can always file the holes down. What I did was drill two small holes on each sides (left and right) of key slot. Then I dremel the top and bottom of each key slot from hole to hole. Punch out the cut-out part of the key slot and use jeweler's files to file down the sides (especially the drill holes) and the top part of the slot for a clean look.
 
Most larger hobby shops or hardware stores should carry sets of small files. I found a set of 8 or 10 in a little plastic pouch at Ace Hardware. It was around $12 or so.

For sanding, I usually start with a 'medium' grit; maybe 200, to remove more material, then work to a finer grit. Be careful when sanding. Work slowly so you don't remove too much material. It's easy to take it off, but harder to put it back on! ;)
 
I forget is the higher grit you go the finer the paper right? 400 is finer than 200. :)

that is correct. the higher the number the finer the grit. also automotive grade sandpaper (black stuff) can be used to "wet sand" so you get a nice smooth finish between base coats and primer coats.
 
Ah helmet prep, my old adversary :lol: I'll admit I HATE every bit of it, especially trimming the visor, my last Dremel died at the hands of my FPH and whilst trimming that thing I was so scared of slicing through a mandible it took me about a week, and the amount of resin dust I've washed out of my hair/eyes/clothes/nostrils but when you finish and your bucket is sat there all primered and ready to go theres no better feeling (y)
 
I MIGHT CUT A MANDIBLE OFF :eek::eek::eek:!!!!!! I AM REALLY FREAKED OUT NOW :cry:cry!!!!!


LOL :lol:

Sorry couldn't resist. Your replies are giving me some confidence and momentum. And for that I say thanks....and if I mess up its all your faults ;).
 
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Well for what it's worth I just finished cutting out the visor in my Rubies Jango Deluxe (a.k.a. my first Bu'cye) and personally I did it with an exacto and a craft knife..honestly I didn't trust my hand to be steady enough to use the dremel...cmae out excellently though!
 
I MIGHT CUT A MANDIBLE OFF :eek::eek::eek:!!!!!! I AM REALLY FREAKED OUT NOW :cry:cry!!!!!


LOL :lol:

Sorry couldn't resist. Your replies are giving me some confidence and momentum. And for that I say thanks....and if I mess up its all your faults ;).

LOL! You'll be just fine!:lol:
 
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