Hey guys working on my scratch build helmet figured I would explain how its going so far. first i started off with a 8$ skateboard helmet from Play it again sports, i took out the liner from the inside because it was a child's size but the outer shell was the right size. I then sized the template From Wizard of Flight to about 105% in adobe. Then i cut out the inner form from Poster board that cost $1.39 from A.C. Moore. I lined up the inner form to the outside of the helmet and hot glued it in place, i then cut out the outer form from cardboard from a regular large cardboard box a package came in earlier this week. I glued that to the inner form and heres what it looked like....
After that i then covered the holes in the helmet with more poster board then i made the side ear covers out of more cardboard. Then I had some fun with Fiber Glass using Bondo Glass which was about $12 from walmart.
Thats all for now more pics to come as I file and Bondo the bucket tomorrow!!!