New Scratch Helmet

Okay, since it is Friday, I was able to do some more work. Now, I can't wait until tomorrow!! I was able to widdle down more of the lower ear cap piece that goes under the range finder. I marked off the angle of the lower piece with a Sharpie and then went to work! Then I sanded it down as best I could and the result is what you see in the picture. Next, I will complete the top rangefinder piece as well as fix some of the imperfections on the lower ear cap piece. Hopefully, I can finish the other ear cap over the weekend!

Eric

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I continued with the easr pieces. I cut out parts of the range finder cap using foam board to "build" it up. I cut the same shapes out of the Sintra for a stiff base. Next will be piecing them together and using some Bondo to strengthen them into a solid looking piece. I also started the other ear cap piece. I used all Sintra pieces and found that when I bent the "U" shaped piece into place, it bowed out in the middle and looked a little awkward. So, I cut to strips and Super Glued them into place in the edge of the "U". Now it has good strength to hold the proper form. I did make them a little too wide though so I will trim them down; you can see in one of the photos that it causes the edges of the "U" to go beyond the base piece. SO, a little sanding and trimming and it should be good to go!

More to come later!
Eric

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Hi Brent, that is actually eight pieces of 2mm Sintra to form the "upright" and angled edge (one whole piece and then trimmed and sanded to form the angle), then it was glued onto another 2mm piece as the base of the lower ear cap piece.
 
You got some crazy skillz dude! This is a treat to spectate! :cheers Keep it coming (y)

Peter
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"With great power comes great responsibility"
 
I'm definitely going with Sintra. I'll have to get some foam board as well now.

Going to follow this thread and Antman's. This Forum has changed my life forever...
 
Hey Brent, your question prompted me to take a look at my lower ear cap again and I noticed that I needed to add another 2mm layer to it. I do not know if that was the intent of your question, but thanks for getting me to look at it again!

Eric
 
OKay, today was a busy day so I was not able to get as much done as I had wanted; however, I was able to add one layer to the back of my lower ear piece and complete initial construction of the left ear piece. I blocked together five pieces of Sintra and tomorrow I will widdle away and do some more sanding to create the angle of the lower ear piece. These pieces will actually need a little refinement (in my opinion) before they are attached to the helmet. I am also debating about casting the lid and whether I should cast it with the ear caps on or off. I am also debating before attaching them whether I should make a mold of them as well, depending on the final result! Enjoy the photos, any comments or thoughts on today's post, let me know!

Eric

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My question about the Sintra layers was only for my benefit once I get to this step... I am no where near there yet but thought it would be good to know when that happens.

I have no idea what order you should do with the helmet and the ear pieces... I hope it goes well for you and you dont wreck your ears. Maybe just use your Sintra ears for a mold... I want to see how you mold these things in photos.

Good luck!
 
Sorry gang, not much time the last couple of days for scratch building. I was only able to get a couple of things done. I whittled down the left ear cap piece for the proper angle, however I found some imperfections. SO, same as I am going to do with the other two pieces, I need to Bondo them and then sand them into a perfect shape before priming and finally casting a mold. This week I purchased a kit by Allumilite for molding and casting small items (such as ear caps!) - $70, at a local hobby shop here in CT -. I will either add that to this thread or make a new one once I get to it. But, after the weekend, I am working at a local University (Wesleyan) and I may have an opportunity to use some of their shop machines to sand, cut etc. for professional looking results!! COOL!!

More to come soon!
Eric

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Your making great progress with this. I've used W.O.F's templates for my sintra bucket. They are so good and the finish was so tight that I've ended up casting it in UPVC resin. Do you intend to cast it? Or is it just going to be a one off? Either way, The use of a cycle helmet for the dome seems to be a good idea, as to make the dome out of 3mm sintra, sand it to shape, blather it in bondo and sand, sand and sand again was a S.O.B to do. Looking forward to see how this turns out :)
 
Thanks, appreciate the comments! My goal is to cast it. I need to learn more about doing it though before I get to that point. I have watched a lot of you tube vids and seen multiple web sites on it, but I have not seen someone go from mold to cast in one complete shot. SO, naturally I have a lot of questions. There was a great video on making the 300 helmet, but there was no video I saw on making the actual mold and how to get to the point of casting the helmet. So, I have a lot to learn still. But, yes, that is the ultimate plan. Then, hopefully as I continue with the rest of the costume, I can mold and cast multiple pieces!

Eric
 
those ear caps look awsome. if you do make casts of the ear caps i would be interested in buying some....i am new here and was wondering where you guys get all the sintra from i can't semm to find any.
 
I picked mine up at a sign shop called FastSigns here in CT. I am not sure if they have locations in Alabama, but, you can get Sintra at just about any sign shop I believe. It can get pricey though depending upon the thickness. I purchased a 2mm 4' X 8' sheet for $65. and so far I have used a little less than half so far. The Jet Pack will use a lot, I am sure.
 
Okay, today I decided that it is time to get back to correcting the helmet in preparation for adding a strengthening layer of fiberglass to the inside of the helmet. To do this I need to add the craft ring into the lid. I purchased a 10" and a 12" ring and decided to hack up and slightly bend the 12" into place and see how that works. In the photos that I have, I took before and after so that you can see if there is a difference. Once I have eliminated the irregular shape, I will then hot glue the ring into place and then add the fiberglass.

E

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I bought it at a local craft store here in the US. Called Joanne's Fabric. It is called a craft ring (from what I was told). Some people use them to make "Dreamcatchers". It is a brass ring basically. The tag on the ring gives a web address of www.darice.com. A company from Ohio. The item number on the tag is #17158. Hope that helps!

E
 
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