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  1. ToEleven's Avatar
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    Jan 8, 2016, 10:21 AM - Yet another ToEleven scratch build #1

    For the past several weeks I've been working on a new helmet which I plan to mold and cast. I'm using Rafalfett's V2 templates as a base for the helmet with a few tweaks along the way. I'm not intending for this to be a wearable helmet...inspired somewhat by Terminal Fettler's build from the scratch build sticky.

    I hope that maybe some of what I'm doing would be helpful for others who are foolhardy enough to sink their time into scratch building.

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    I used rafalworks from 3dwarehouse.com helmet to get my dome base started. This is not actually how the file represents it. I had to separate the dome and slice it in another program.


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    The base is foam core poster board. You have to trim height from the supports if you want to use this material since it's a bit thicker than the templates allow for. I also use 2mm Sintra/Celtec for the covering.

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  3. ToEleven's Avatar
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    Jan 8, 2016, 10:38 AM - Re: Yet another ToEleven scratch build #2

    The dome is probably the most difficult part of the helmet to get right. I've been through many stages of bondo/sanding/primer to get it figured out.

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    It's starting to take shape, but the front profile is still too square and the dent is a little too...denty.
  4. ToEleven's Avatar
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    Jan 8, 2016, 10:48 AM - Re: Yet another ToEleven scratch build #3

    More dent work, dome sculpting , etc.

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  5. Member Since
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    Jan 8, 2016, 2:38 PM - Re: Yet another ToEleven scratch build #4

    You are a helmet making machine.
  6. Jan 9, 2016, 2:15 PM - Re: Yet another ToEleven scratch build #5

    When you say that you used Sintra for the covering, could you please specify which part of the helmet you utilized it with? I am wanting to start a build, and I am curious as to whether or not I should use mat board or Sintra.
  7. ToEleven's Avatar
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    Jan 9, 2016, 2:56 PM - Re: Yet another ToEleven scratch build #6

    You would basically use 2mm sintra for the entire build except the cross-section supports. I used foam core for the supports. If you go with sintra get some decent name brand super glue. Or CA glue at a hobby supply. I use hot glue gun to hold the support sections together. My first build was with framing matt board 1/16". It wasn't terrible, but I definitely prefer sintra. If you need to bend it get a teapot going on the stove and use the steam from the spout to soften the sintra to shape it.

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  8. drokkul's Avatar
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    Jan 9, 2016, 3:29 PM - Re: Yet another ToEleven scratch build #7

    Be careful with Sintra. Heating causes release of hydrogen chloride gas.

    From the MSDS for Sintra:

    SECTION VI - HEALTH HAZARD DATA
    These products are not considered to be a health hazard in the form in which they are sold (sheet, panel). However, if theseproducts are abraded, melted, welded, cut or processed in any manner that causes release of fumes or dusts, hazardous levelsof fumes or dusts may be generated from this product

    EFFECTS OF OVEREXPOSURE:ACUTE: Physical irritation of the eyes may result from overexposure to high concentrations of dust from certainfabricating operations.Repeated skin overexposure to antimony trioxide can result in skin irritations.

    CHRONIC: Repeated long term inhalation of antimony trioxide may cause inflammation of the upper and lowerrespiratory tract and/or fibrosis. Antimony has been determined by IARC as a Group IIB carcinogen.Studies have shown that workers exposed for long periods to·high concentrations of respirable PVC dust may retain thedust in their lungs. There is no evidence of a toxic response associated with such PVC dust retention.Repeated long-term inhalation/ingestion o f lead may lead to weariness, headache, severe constipation and colic. It hasbeen determined that lead is a reproductive toxin.
  9. ToEleven's Avatar
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    Jan 9, 2016, 4:10 PM - Re: Yet another ToEleven scratch build #8

    Thanks @drokkul this is good info. So many nasty chemicals involved with this hobby.
  10. Cyris's Avatar
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    Apr 2011
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    Jan 9, 2016, 5:34 PM - Re: Yet another ToEleven scratch build #9

    Hey, another ToEleven build. Awesome!

    AND you plan on using this as a potential plug to mold and cast? And you plan on selling some??? If that's really the case, then I wouldn't mind being the first in line for one! lol

    I had attempted one before with an old WOF build I did years ago, and I was actually thinking of doing something similar with the RWHv2 for some future projects, but I ran into some sizing issues a while back, and I haven't decided if I'll get back to it. As rewarding as it is, scratchbuilding can sometimes be a chore. But you're plugging right along, and it's looking fantastic already!

    Do you know how you plan on tackling the ears? Like using block molds or perhaps just making them a part of your build? Are you thinking of turning these into full-fledged kits or just focusing on helmets?

    Either way, I wish you good luck! I'll have to keep an eye on this thread.

    P.S. Even though I haven't really messed with sintra myself, perhaps using an organic respirator might help with fumes when heating? As weird as it might be to wear that in the house, you can never be too cautious!
  11. ToEleven's Avatar
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    Jan 9, 2016, 8:01 PM - Re: Yet another ToEleven scratch build #10

    Quote Cyris said: View Post
    you plan on using this as a potential plug to mold and cast? And you plan on selling some??? If that's really the case, then I wouldn't mind being the first in line for one! lol
    If this turns out like I want it to... I would be open to selling castings. 1st I'm going to test them out on a few friends and family who want a casting, and see how the fit and look is. I'll definitely hit you up when I can do some.

    As far as the ears go, they will be block molds. I'll be starting the prototypes out on a cnc router with 3d print files. If the router performs well enough i'll make aluminum stalks like I did for my kid's buckets.
  12. ToEleven's Avatar
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    Jan 12, 2016, 11:15 PM - Re: Yet another ToEleven scratch build #11

    Bondo-sculpting the mandible and cheek area.

    Shaping and gluing in the cheeks is such a pain...they seriously seem like they should be easy, but noooo.

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  13. bassplayer82's Avatar
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    Jan 13, 2016, 4:45 AM - Re: Yet another ToEleven scratch build #12

    Wow man that looks sharp!!! Good work!
  14. ToEleven's Avatar
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    Jan 15, 2016, 9:39 AM - Re: Yet another ToEleven scratch build #13

    Some progress...

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  15. Raizo's Avatar
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    Jan 15, 2016, 9:59 AM - Re: Yet another ToEleven scratch build #14

    Nice!!
  16. Jan 15, 2016, 11:10 AM - Re: Yet another ToEleven scratch build #15

    Never seen a dome made like that looks outstanding
  17. Member Since
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    Jan 15, 2016, 12:27 PM - Re: Yet another ToEleven scratch build #16

    Really clean! This one is going to be good enough to mold and sell cast kits for sure.
  18. ToEleven's Avatar
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    Jan 18, 2016, 10:58 PM - Re: Yet another ToEleven scratch build #17

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    This dent is finally starting to make me happy...for now.


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    Happy little keyslots.


    A few with the dome.
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  19. Member Since
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    Jan 19, 2016, 12:41 AM - Re: Yet another ToEleven scratch build #18

    Man... Mine sucks!
  20. Jan 19, 2016, 2:49 AM - Re: Yet another ToEleven scratch build #19

    Shmoooove the key slots look great, I have to make mine quite flush so I can get 'my' dome inside the dome
  21. ToEleven's Avatar
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    Jan 19, 2016, 8:24 AM - Re: Yet another ToEleven scratch build #20

    Quote Elusive said: View Post
    Man... Mine sucks!
    Keep in mind this is my 4th build...5th if you count the one I threw away.
  22. ToEleven's Avatar
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    Jan 25, 2016, 3:10 PM - Re: Yet another ToEleven scratch build #21

    I've been tweaking this thing endlessly...getting closer to the finish line.


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    Ear platforms, turn signals & Ears.


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    I have a little sanding and tweaking left, but this is about 90% there.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  23. Cyris's Avatar
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    Jan 25, 2016, 10:33 PM - Re: Yet another ToEleven scratch build #22

    That is looking fantastic! I'm also impressed by how quickly you've made such progress, though if this really is your fourth build, I suppose it's no surprise you'd be a Jedi Master at scratchbuilding by now. Awesome job!
  24. RafalFett's Avatar
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    Jan 26, 2016, 12:01 PM - Re: Yet another ToEleven scratch build #23

    This have to be the best scratch built/3D printed/CNC'd helmet I have seen so far! And it looks way better than most of the mass made helmets. Keep up the great work!
  25. ToEleven's Avatar
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    Jan 26, 2016, 3:40 PM - Re: Yet another ToEleven scratch build #24

    Thanks Raf, I'm honored! I could not have done it without your prior work.

    Quote RafalFett said: View Post
    This have to be the best scratch built/3D printed/CNC'd helmet I have seen so far! And it looks way better than most of the mass made helmets. Keep up the great work!
  26. RichardJones's Avatar
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    Feb 2012
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    Jan 27, 2016, 7:31 AM - Re: Yet another ToEleven scratch build #25

    Quote Cyris said: View Post
    And you plan on selling some??? If that's really the case, then I wouldn't mind being the first in line for one! lol
    !
    This build looks amazing! I will be watching for that sales thread!

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