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  1. RBF's Avatar
    Member Since
    Jan 2005
    Posts
    2,173
    Nov 29, 2008, 6:36 AM - Re: New Scratch Helmet #101

    an amazing bucket, and an amazing repair job!!! this is an amazing project!!! keep it up!!!
  2. Puritan's Avatar
    Member Since
    Nov 2008
    Posts
    35
    Nov 30, 2008, 12:21 AM - Re: New Scratch Helmet #102

    Another possible solution to the problem with the holes in the top, is to coat the whole dome with a thin layer of bondo, then when you sand it down, it should sand down evenly.
  3. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    130
    Nov 30, 2008, 5:46 PM - Re: New Scratch Helmet #103

    Quote madmanmoe64 said: View Post
    Just a thought. The problem with the bike helmet holes arises because the filler material (bondo or red paste) is less tough than the original plastic. So when you sand the area the filler sands down faster than the bike helmet and you get the dips.

    You need to find a filler that is of a similar toughness to the bike helmet. No idea what sort of filler that might be.
    I had a similar problem because I used two different types of polyfiller on my bucket.
    Actually, the "Red Paste" is Bondo, I found it in a single tube that does not require mixing. I took to the lid this past Wednesday and found that by lightly sanding teh area, it seemed to fill the holes better, and then with the new primer that I used called Dupli-Color Filler Primer from an automotive store, it wound up covering the holes and the crack lines after my last bit of Bondo-ing quite nicely. I just have a little more filler work to do and a little more sanding and I will be ready for the keyholes in the back and then the Dent!

    Eric
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  4. Member Since
    Dec 2008
    Posts
    12
    Dec 9, 2008, 1:42 PM - Re: New Scratch Helmet #104

    Short of fiber glassing the holes I don't think you can find a 'filler' that would be as strong as the plastic helmet. The problem with using filler to fill holes in plastic is also due in part to the plastic being very flexible as well as hard. I would suggest trying a skim layer over the larger surface of the holes and sanding down in stages.

    Rough shape with 120 grit so you don't take too much material off or make deep groves (80 grit if you apply too much) then step it down to 220, 320, 400, 600 and 1000. Pressure is key in sanding but the good news is that you're in control. Try using a foam sanding block or a sponge to sand with.
    -Aaron.
  5. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    130
    Aug 18, 2009, 10:02 AM - Re: New Scratch Helmet #105

    Hi Gang! Sorry I haven't been posting, I actually suffered an injury and I have been out of work, etc.etc. But!! I am back and ready to get going again. I literally have not touch Boba since my last posting and I am missing it, the forum, the support and all of the talented people that make this site impressive! Regarding my injury, here is the funny thing....I now have a dent on my head! Well, it has healed a bit since it happened, plus it is on the wrong side, but I took a baseball of the head and it literally dented my own dome! I couldn't wait to post up and tell everyone how funny it was, but the sad part was every time I touched a computer, something in the screen flicker made me sick to my stomach. In any event, I am back, I will be hard at work and posting in no time. Anyone have any really informative threads they recommend I look at? Happy Building!!!

    Eric
  6. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    130
    Aug 21, 2009, 5:29 PM - Re: New Scratch Helmet #106

    Hey gang, looking for some assistance/suggestions. I have been annoyed with how the cheeks look. I notice that in the movei reference photos, the "cheekbone" is rather defined. Is this because of a good paint job or are the cheeks outlined against the upper cheek piece really defined? Or both? I was thinking of adding an additional piece of Sintra to outline the cheeks and resolve my dilemma. Thoughts or suggestions?

    Eric
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  7. goodus10's Avatar
    Member Since
    Mar 2009
    Posts
    79
    Aug 22, 2009, 3:24 AM - Re: New Scratch Helmet #107

    Hi there, I'm fairly new to all this myself, but if it was me, I would proabably try to define the cheeks with sanding rather than add another layer. Adding another layer would make the cheek area shallower, which is a problem I had do deal with when I attached the mandible pieces in the wrong place on my first build. It would of course depend on how thick the additional layer was. It may be the easier route. I know how everyone 'loves' sanding. Glad to hear you're feeling better.
  8. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    130
    Aug 23, 2009, 10:45 AM - Re: New Scratch Helmet #108

    Ah yes, the dreaded "S" word. The sintra I use is only a little more than 1mm thick. Fortunately I have reinforced the inside with fiberglass in case I sand too much. Any other ideas? THoughts? Hopefully this week I will be heading out to find some silicone here in CT to make my mold so I can cast this helmet to make more! Anyone out there in the CT area? I would love to hear from you.
  9. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    130
    Aug 31, 2009, 9:51 PM - Re: New Scratch Helmet #109

    well, it has been a real strugle for me trying to get those cheeks right. I am thinking of maybe either cutting them out and replacing the piece after sanding, or molding this helmet and then cutting out the cheek. Is this why some of you have had various versions of your helmet? If anyone has some suggestions on the cheeks, please let me know as I am really struggling with this.

    Thanks,
    E
  10. Member Since
    Jul 2012
    Posts
    3
    Aug 11, 2012, 8:09 PM - Re: New Scratch Helmet #110

    Very inspiring work! How does it look four years on?
  11. kebh020727's Avatar
    Member Since
    Aug 2008
    Posts
    130
    Aug 12, 2012, 11:26 AM - Re: New Scratch Helmet #111

    Thanks man, I appreciate the comments. This has been a fun project but I had put it on hold two years ago. My wife and
    I had put our condo on the market and I was forced to close up shop. We finally sold it after two years on the market
    And moved into a house in June! I now have a space that will be my very own Boba workshop! But I need to knock out a
    Couple of house projects that need my attention first. Hopefully by end of September for early October my new workspace
    Will be ready for business. I'm truly excited to be back on the bucket build again, it is a rewarding and challenging project
    For anyone who loves "The Dented Dome"!
    E

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