Here is the outcome of my MR Referb mold project.
The purpose for this was to give me the best available base helmet to make EVERY different version that ever was from the super trooper helmet to the ROTJ.
I made the mold as a one piece glove mold to allow a seamless pull as well as just an easyer mold to make. I did it with a brushable urithaine rubber that i built up in coats. I made the first coat off black so when I brush in the gel coat (white) so I know I have full coverage.
The mother mold or outer support shell is made out of Ultracal. This was easy to sculpt as it set into the proper even sides and was reinforced with hemp.
Here is a quickly trimmed and quickly primed firt pull. I am pretty happy with it and cant wait to get going on all my helmet versions.
Becase I taped the keyholes shut instead of filling them with clay, all you have to do is shave down the back of them from the inside and it opens them up with no trouble and you dont have to do the normal pain staking work of drilling them out and filing them down. Though its harder to fiberglass this way due tot he undercuts of the keyholes.
The visor correction was originally going to be done by cutting but I knew in my heart that it could be done without this and gave it a shot. I am very happy with the end result.