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  1. Member Since
    Oct 2012
    Posts
    74
    Dec 18, 2012, 5:18 AM - Skateboard/Matte board Helmet... #1

    After lurking on these forums for years and debating wether or not I wanted to start the long process of building my dream costume, I have finally jumped in head first. I work nights, so this project is perfect for me to work on during my days off in order to keep me up all night long.

    I have never done the whole costume construction thing because it seemed like such a huge time investment. Using the awesome templates found here I have finally started my first build.

    I knew full and well that I was getting myself into a huge undertaking, so I decided I would document everything along the way since other people's posts helped me decide which direction I wanted to go with my build and how to get started. Hopefully my thread will work to help some people as they troubleshoot and problem solve their own builds.

    I started out with some quick mock-ups to get everything sized/fitted correctly....
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    Once I was comfortable with the sizing and using the templates it was time for my first of what will be many shopping trips. 2 sheets of black matteboard not pictured... (All from Wal-Mart and Hobby Lobby)
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    Time to cut out the interior padding and shape the dome...
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    Heated to hold shape...
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    Checked to see if the dome would fit the lower sections...
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    Cut the lower sections out of matteboard and attached to the dome...
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    Bondo was added to the seam between the dome and then inner form, outer form added and cut...
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    Holes on dome have been closed with bondo...
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    Added layer after layer of bondo and spot putty to smooth the surface, sanded many many times...
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    After the surface was smooth I moved on to primer, bondo, spot putty, sand, repeat, repeat, repeat...
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    Dented added by cutting out a hole and then adding an inset piece of plastic behind the dome to add filler to...
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    Keyhole cut in rear...
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    More sanding and painting...
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    Bending the plastic cut from a thin plastic "For Sale" sign, hair dryer used to heat and cool the plastic to shape...
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    I am obsessed with sanding this thing to get it was smooth as possible, but it is getting closer to meeting my standards...
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    Shopping trip for spray paint based on suggestions on these forums... (All at Home Depot)
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    Sprayed on some colors to test...
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    Now I am going to go back and resin/fiberglass the interior before moring on to the detail paint.

    Thanks for the inspiration guys, I am having a blast with this and wish I had started 2 years ago when I found this community.
    Last edited by Lostsaint; Jan 8, 2013 at 3:34 PM.
  2. StrumFett's Avatar
    Member Since
    May 2008
    Posts
    213
    Dec 19, 2012, 1:58 AM - Re: Skateboard/Matte board Helmet... #2

    Awesome job!
    I love the way you made this helmet
  3. Member Since
    Oct 2012
    Posts
    74
    Dec 19, 2012, 3:04 AM - Re: Skateboard/Matte board Helmet... #3

    After doing the sanding and painting, I wish I had used Sintra instead. The matte board tends to peel a bit when sanding bondo on paper.

    It has still been a blast though.
  4. Member Since
    Oct 2012
    Posts
    74
    Jan 8, 2013, 3:34 PM - Re: Skateboard/Matte board Helmet... #4

    Updated the color test from spray cans.
  5. Jack7226's Avatar
    Member Since
    Dec 2012
    Posts
    19
    Jan 9, 2013, 8:55 PM - Re: Skateboard/Matte board Helmet... #5

    That right thar looks sweet. I tried to find a skateboard helmet in my area but the ones i found werent shaped right in the front. I opted for an umpire helmet. Cant wait to see more
  6. Mar 15, 2013, 10:48 PM - Re: Skateboard/Matte board Helmet... #6

    Did you intend to use the skate helmet from the start or did you originally try out the templates for the paper dome?

    I have been lurking the forums for a few years now myself, but have only recently signed up on here to ask the more direct questions to aid in my construction efforts. Thanks for the good insights and pics to help make this build that much easier and more guided!

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