I've been wanting to make a Fett helmet from scratch for sometime now, but couldn't get my head around how to do it. After thinking long and hard about it, I came up with the following concept. Let me know what you think.
MANDO HELMET FABRICATION CONCEPT
STEP 1 - THE FORM
The form will be created by first making an MDF framework using the top, side and left/right profiles from the Wizard Of Flight templates, scaled up by approx. 15%, to match the size of the Hasbro helmet. This framework will then be filled in with pink styrofoam insulation, and sculpted to shape. It will then be filled and sealed with drywall joint compound and given generous layers of primer and clearcoat. Separate forms will be made for the dome and the lower half of the helmet.
STEP 2 - FIBERGLASS
The form will then be coated with generous amounts of mold release (Turtle Wax?), and a first layer of resin will be applied, followed by 2 or 3 layers of fiberglass mat. An additional 2 or 3 layers of resin will be applied after that.
STEP 3 - CUTTING
After removal from the form, the helmet pieces will be trimmed and cut, following the same templates used to make the form. Any remaining pieces of the helmet will be fabricated from styrene and MDF.
That's the concept for now. The only material I'm missing is the fiberglass mat. I'll have to look for a place to purchase it inexpensively. I'll be happy to hear everyone's thoughts on the feasibility of this idea. Thanks!