New Helmet Sculpt - *UPDATE* 6 Jan

bobamaker

Active Hunter

• Dec 30, 2004

• #21

OK, I have been working on the keyslots today, so I've produced a little step by step picture guide. The slots are made from 3mm sintra, hopefully the pictures will make sense. I just need to glue this panel into the cutout at the back of the helmet with epoxy filler now and do more sanding! Oh, I took a shot of the inside also, it's a bit messy in their but this won't matter when I make the molds!

I will try my best to photograph the remaining stages as the helmet progresses... I get too involved sometimes and go steaming ahead!

 

Last edited by a moderator: Jul 24, 2017

Blastech

Well-Known Hunter

• Dec 30, 2004

• #22

Pretty neat. How in the world did you do the dome? Looks great!

 

Last edited by a moderator: Jul 24, 2017

bobamaker

Active Hunter

• Dec 30, 2004

• #23

Blastech wrote:
Pretty neat. How in the world did you do the dome? Looks great!

Click to expand...

This was the bit that took a lot of thinking about, but here's what I did:

I borrowed a friend's motorbike helmet which was similar in shape but not identical to what I wanted. I mixed a bowl of plaster (quite thin and runny) and dipped the helmet in until dry (about 6 minutes). I removed the helmet to reveal a very smooth dome shape. I then rubbed a layer of petroleum jelly on the inside of the plaster mold, I then painted a layer of gelcoat (thickened with talc to ease sanding) on the inside of the mold. When dry, I added a layer of fibreglass tape and resin (only one thin layer to keep it weak and flexible). When dry, I removed from the mold, the shape was quite good, but a little too perfect and too round. I placed the fibreglass dome in hot water for a few seconds to make it pliable, I then pressed in the sides slightly to give me a better shape (it was a little too pliable, I ended up with a few humps!). Finally I cut off the excess fibreglass and added plenty of epoxy filler in the humps and sanded. I sprayed a quick coat of primer to reveal any imperfections (plenty), repeated filling and sanding for an hour or so to fine tune the shape. Once I had built the sides I then strengthened the dome on the inside with more filler (it's amazing how heavy this filler is when dry, this bucket could sink a battle ship!)

Hope you can follow these...

DAZ

 

Last edited by a moderator: Jul 24, 2017

Macantosh 1138

Active Hunter

• Dec 30, 2004

• #24

wow, doing this is inspiring me to try to take on the task of a custome helmet!

were is this cardboard tutorial...?

 

Last edited by a moderator: Jul 24, 2017

bobamaker

Active Hunter

• Jan 2, 2005

• #25

OK, as promised, I've taken pictures of the next step of my helmet, this is the RF Housing Assembly.

I started with a digital picture of the right side of the screen used helmet, I scaled it up to the correct size then traced the exact shape.

I cut the relevent shapes from 3mm and 5mm sintra (shown here). These are now ready to glue together and attach to the helmet (I've highlighted the picture with a red border to show the part that I'm constructing). There will obviously be lots of filling and sanding required. The earcap will be the thinner version as seen here.

 

Last edited by a moderator: Jul 24, 2017

Rammage

Active Hunter

• Jan 2, 2005

• #26

Awesome helmet, man! Hows about sculpting a Jango helmet next?

 

Last edited by a moderator: Jul 24, 2017

A

alfredsson

New Hunter

• Jan 2, 2005

• #27

nice progress...:cheers

 

Last edited by a moderator: Jul 24, 2017

Macantosh 1138

Active Hunter

• Jan 2, 2005

• #28

looking forward to the new photos!

 

Last edited by a moderator: Jul 24, 2017

thksdad

Active Hunter

• Jan 2, 2005

• #29

Well DAZ, as always, you have done an awesome job. i can't wait to see the final product. it looks great right now, but, man, when its all painted, whooooweeeee...that will be sweet!!!!
Michael

 

Last edited by a moderator: Jul 24, 2017

bobamaker

Active Hunter

• Jan 3, 2005

• #30

Rammage wrote:
Awesome helmet, man! Hows about sculpting a Jango helmet next?

Click to expand...

When this has been molded I may alter this master and make a Jango version, it depends whether there is any interest.

 

Last edited by a moderator: Jul 24, 2017

cal196

Well-Known Hunter

• Jan 3, 2005

• #31

I know this question may seem far off but -ballpark- how much are you charging per helmet?

 

Last edited by a moderator: Jul 24, 2017

J

jeezycreezy

Active Hunter

• Jan 3, 2005

• #32

That's looking really good Daz. Most impressive.

Cheers!
TJ

 

Last edited by a moderator: Jul 24, 2017

bobamaker

Active Hunter

• Jan 3, 2005

• #33

cal196 wrote:
I know this question may seem far off but -ballpark- how much are you charging per helmet?

Click to expand...

It depends largly on how people will want them finishing. If they are supplied with the T-Visor and keyslots cut out, sanded and primed and supplied with a T-Visor then I would guess around the £150 mark, but less if I just supply them trimmed along the bottom edge. I will more than likely get a run going here and offer a discout though.

 

Last edited by a moderator: Jul 24, 2017

sithlord23

Well-Known Hunter

• Jan 3, 2005

• #34

Yeah, that is great work! Keep the progress pics comin!

 

Last edited by a moderator: Jul 24, 2017

S

slave1pilot

Well-Known Hunter

• Jan 3, 2005

• #35

bobamaker wrote:

cal196 wrote:
I know this question may seem far off but -ballpark- how much are you charging per helmet?

Click to expand...

It depends largly on how people will want them finishing. If they are supplied with the T-Visor and keyslots cut out, sanded and primed and supplied with a T-Visor then I would guess around the £150 mark, but less if I just supply them trimmed along the bottom edge. I will more than likely get a run going here and offer a discout though.

Click to expand...

Please keep us posted.
How much is that $US ?

 

Last edited by a moderator: Jul 24, 2017

A

alfredsson

New Hunter

• Jan 3, 2005

• #36

150£ is around $285

 

Last edited by a moderator: Jul 24, 2017

Geo

Active Hunter

• Jan 3, 2005

• #37

Ouch!

 

Last edited by a moderator: Jul 24, 2017

bobamaker

Active Hunter

• Jan 3, 2005

• #38

That price includes cutting out the visor, keyholes, sanding and painting all the pieces in grey primer. The cost for one just trimmed along the bottom edge will be more like £100 ($190).

It's still early days yet.

 

Last edited by a moderator: Jul 24, 2017

cal196

Well-Known Hunter

• Jan 4, 2005

• #39

Awesome.

 

Last edited by a moderator: Jul 24, 2017

Master Jedi Allma

Active Hunter

• Jan 4, 2005

• #40

The sculpt is looking awesome!
what other parts are you doing as well as the helmet buddy?...
Nice to know there someone here in the UK doing this stuff...

Mason...
(ipswich, UK)

 

Last edited by a moderator: Jul 24, 2017