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  1. MisterCrash's Avatar
    Member Since
    Aug 2007
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    6
    Aug 10, 2007, 2:05 PM - Scratchbuild "Skydivinghelmet" #1

    Hello, I know I'm a bit out of place in here. But I found a lot of useful info in these forums. I hope my project will be welcomed with open arms. I am seeking for good advice since this is my first scratchbuild project, with no experience what so ever. I will keep posting my progress with pictures and stuff so others can learn from it as well. So here goes: The project consists of 3 chapters. First, building my positive out of clay. Second making a mold out of plaster. And third building the helmet with carbonfibre and glassfibre. I know this project can cost me a lot more than buying a new premade helmet, but I'm shure you guys know why I'dd wanna do this...

    Chapter one: "Sculpting my positive".

    1. I built an armature for my helmet out of wire of clothing hangers and mesh wire. So it fits the inside of my previous skydiving camerahelmet.
    2. Applied lot's of SuperSculpey on top of my armature until all outside was covered, and started sculpting the main form.
    3. I added more detail to the helmet for the topmount camera (that will be later boxed inside) and place for two audible altimeters... I tried to smooth out the dome's surfaces just by rolling a big *** battery from my radio on it. I just don't have any tools hahaha. Improvising all the way.
    Look at the attachements if you need visual confirmation.


    So this is the point at where I'm at. And here is where I need your expertise on the following questions:
    1. What other tools than a simple battery can I use to make the curves flawless?
    2. How can I smooth out all of the surface the best way. I read some stuff about rubbing alcohol.
    3. Do I need to cover the inside of the clay helmet for baking?
    4. Will my mother get pissed if she returns after a week of holiday if I bake this stuff in her oven?
    5. I'm not shure there is air trapped inside because I worked the sculpting by placing layers on each other, will this give problems baking it?
    I would really appreciate your help and hope to get to the next chapter next week. If you find a lot of spelling errors, please don't hang me for it. I learned it all by watching TV hehehe.
    Attached Thumbnails Attached Thumbnails 1a-jpg   1b-jpg   2a-jpg  

    2b-jpg   3a-jpg   3b-jpg  

    3c-jpg  
  2. askywalker98's Avatar
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    Aug 10, 2007, 2:45 PM - Re: Scratchbuild "Skydivinghelmet" #2

    That's looking great! My brother skydives, and bought a carbon fiber helmet that looks similar to the one your building. He jumps with a Sony HD Camcorder on top, and recently built a plate so he can have the Sony Camcorder next to my Canon 10 MP SLR. Great stuff!

    How many cameras are you planning on jumping with?

    Best of luck!
  3. MisterCrash's Avatar
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    Aug 10, 2007, 2:55 PM - Re: Scratchbuild "Skydivinghelmet" #3

    I'm planning to make the topmount box for "yes you guessed it" the Sony HighDef series. But there will only be space for one camcorder, no stills camera. Because I'm mostly doing freefly, no camerawork. Ps; the HC-series now have dual rec function to take pictures while filming. I'm just waiting until they make a lanc-control for it. Who knows if I'm bored waiting I'll start on my own again hehehe.
  4. MisterCrash's Avatar
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    Aug 2007
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    Aug 14, 2007, 4:49 AM - Re: Scratchbuild "Skydivinghelmet" #4

    Well I don't know what to say, I have no patience... So I finished some detailing and put it in the oven. I gave it 40 minutes at 135C. It looked great when I took it out, but after cooling down I was surprised to see a few big *** cracks in my sculpture.

    So now, do any of you guys know if I can repair these cracks? I would like to have a smooth as possible surface before taking it to the next step.
    Attached Thumbnails Attached Thumbnails 4a-jpg   4b-jpg   4c-jpg  

  5. askywalker98's Avatar
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    Aug 14, 2007, 7:38 PM - Re: Scratchbuild "Skydivinghelmet" #5

    The Sony HD does have LANC Control! The stills while filming is alright, but you can only take 3 per filming shot (it stores them to ram, then loads them to your card when you stop recording, I know, LAME!).

    Use some Bondo to fix those cracks. Your going to make a mold for this anyways, so it doesn't matter what smooths it out. Bondo should do the trick. Look around here if you don't know how to use bondo.

    Get a WIIIDE Angle lens for that camera!
    Good luck!
    -Anthony
  6. Member Since
    Apr 2006
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    Aug 16, 2007, 10:34 AM - Re: Scratchbuild "Skydivinghelmet" #6

    Looking good. but if that is going to be a ridgid positive, a plaster mold wont work for you.
  7. MisterCrash's Avatar
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    Aug 16, 2007, 5:13 PM - Re: Scratchbuild "Skydivinghelmet" #7

    Could you elaborate a bit more on why a plaster mold is not going to work for this? And what would be my alternatives...
  8. Member Since
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    Aug 17, 2007, 1:31 AM - Re: Scratchbuild "Skydivinghelmet" #8

    if you have a complex shape with undercuts or places for the plaster to catch on, such as the large deep square indentations on the sides. You wont be able to release it from your mold. your best bet would be a silicone mold
  9. Mojo-Fett's Avatar
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    Aug 17, 2007, 3:07 AM - Re: Scratchbuild "Skydivinghelmet" #9

    What about a 2 part mould... along the centrline (front to back) that would overcome that problem wouldn't it?
  10. MisterCrash's Avatar
    Member Since
    Aug 2007
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    Aug 17, 2007, 4:31 AM - Re: Scratchbuild "Skydivinghelmet" #10

    Yep I was guessing the same thing. And that's what I'm going to try too. I finished the sanding proces (it isn't sanded to perfection). But I'm worried the cracks will expand and eventually kill my sculpt. So this is where chapter one ends. I will be placing my order for the plaster stuff today. You will hear from me again when I get delivery
    Attached Thumbnails Attached Thumbnails 5a-jpg  
  11. Mojo-Fett's Avatar
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    Aug 17, 2007, 8:48 AM - Re: Scratchbuild "Skydivinghelmet" #11

    Cool....
    keep up the good work and keep us posted of your mould progress?
  12. MisterCrash's Avatar
    Member Since
    Aug 2007
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    Sep 21, 2007, 1:49 PM - Re: Scratchbuild "Skydivinghelmet" #12

    Chapter two: "Casting the mold".

    Well, after a small break, and waiting for the "free" plaster, I got to the next step. Casting the mold, and to my surprise it worked out pretty good.

    I used a 2 part cast in a casing as you can see in the following pics. I should have made the clay helmet with some excess because now I had to make dams to fit the casing. But I'm still learning, it's my first helmet you know.

    I divided the helmet in two (greased it up good with spraying vaseline) and used poring plaster to fill it up. And guess what I was out of plaster so I had my brother take me some more from work. Did the second part a few days later, which is today . The vaseline did it's job good. I had no difficulties what so ever taking the mold apart.

    So now I have to fill up the cracks and air bubbels on the surface area. I dont know yet what to use for that (maybe plaster again). If anyone knows pls let me know.

    Then sand it up again and I'll be ready for the next step. PS; the good news is the mold fits around my head. Bad news is I don't really know what it will be like when fibreglassed and foam inside. Anywayz here are my pictures.
    Attached Thumbnails Attached Thumbnails 6a-jpg   6b-jpg   6c-jpg  

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  13. mandosoldier's Avatar
    Member Since
    Jul 2007
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    Sep 21, 2007, 9:43 PM - Re: Scratchbuild "Skydivinghelmet" #13

    LOL you should do a skydiving helmet that looks like Boba Fett. That'd be an awesome sight to see coming down on you

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