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  1. D3ATHF3YD's Avatar
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    Sep 2010
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    Sep 11, 2010, 1:44 PM - Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #1

    Hello all, I just wanted to post some pictures that I've been taking during my latest build. Sorry it isn't Fett related, but my bro beat me to it and it about half way through the build already. This is just a basic as all get-out bondo and fiberglass resin tutorial for n00bs. If you are a vet and see that I jacked something up, let me know.

    First off... you need a pepakura base. I used the 110 card stock.
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    WHAMO! 8 hours of dinking around compiled into 3 images!

    Then you need to apply resin to it to stifffen it up, I used a Bondo brand fibeglass kit. This helps it keep its shape when you get down to sloshing "Rondo" around inside of it.
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    Now that you have let that dry for a few hours, cut up a bunch of fiberglass near your work area. this is important because you won't be able to cut it effectively once you're all gooey.
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    Next, its time to bust out the "Rondo".
    I use a 1:1 ratio of bondo to resin. Then to get the consistency of pancake batter so it will slosh well and self level, I use the clear liquid hardener that came with the resin. You can also use the cream hardener that came with the bondo but it makes a thicker paste that is red.

    I only mix 2 tbspns of bondo and resin each and add approximately 24 drops of hardener. WARNING: you will only have about 3 minutes to work the stuff before it starts to set, then you're screwed. Use less hardener if you want it to harden slower.
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    Also you'll notice throughout my pictures that I started the application with syrofoam cups... which is bad. Foam cups melt when contacted by the Rondo mix and it can get messy. I later opted for aluminum cans which I cut in half. These worked much better.

    Now take that goo and pour it into the piece and use a brush or something to help it around the inside coating every inner surface.
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    Once you get an initial coat in there, I start to apply the fiberglass matting we cut up earlier with the next batch. Just put a dab or two on the mat then press it into place. The mat will pull apart and is lame to work with, there are other alternatives but this is what I had on hand. Just get it in place and dump more Rondo onto it and try to smooth it out.
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    Holy smokes that was easy and fast right?!?! Actually it still kinda sucks and its messy. At this point I would like to thank my beautiful girlfriend for taking the pictures and putting up with the smell.

    Once it is all cured, flip that sucker over and coat the top. Doing this should allow you to sand the sucker's high points down to a more aesthetic roundy-shape later. I just painted it on as this allows you to continually work it and avoid drips and irregularities more which means less sanding later.
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    Once you get that all cured and feel you have adequate thickness to sand down the undesired harsh angles and high points, get suited up to sand (respirator, coveralls, and goggles). Find a location that can get hardcore dusty with rondo and take course grit (like 80grit) and hammer those angles out. If the piece is supposed to have angled parts... just don't sand across those.
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    You can see here there is a color difference as I sanded through the outter coat of Rondo and into the paper, then into the interior Rondo. This is what we coated both the inside and outside for... to get the thickness we needed to round her up. Then once it is sanded and you start to fear you may break through, stop and apply more Rondo!

    Repeat until you are happy with the end result. I have to go finish this sucker right now, I should have more pics up of the finished product in a bit. Good luck!
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  2. D3ATHF3YD's Avatar
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    Sep 11, 2010, 3:00 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #2

    Ok kiddos... got another coat on, I experimented with the cream hardener on the inside this time, hoping it would give me a bit thicker coat on the inside. Apparently it worked out well, I just put a bit too much in and it hardened rapidly, but all is well and my helmet is pink on the inside now.


    And another coat on the outside and I'll be ready to sand again once I get suited up.
  3. D3ATHF3YD's Avatar
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    Sep 11, 2010, 4:00 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #3

    AWWWWWWRIGHT!!! I sanded it down some more, and you can see how much of the original geometry I'm taking off.


    I'm hoping that that cardstock showing through won't be an issue when it comes time to primer and sand this beast.


    You'll also notice when I hold it to the light that it is getting thin spots in it now, so i'm going to backfill those and just keep sanding it down.
  4. saint_nasty's Avatar
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    Sep 11, 2010, 5:59 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #4

    this is probably the best rondo tutorial i've seen. it really helps that i get to watch a piece being built to help me figure out a thing or two about how to do it.
  5. BobaFiend's Avatar
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    Sep 11, 2010, 6:10 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #5

    i didn't know that bondo and resin would respond to the same hardener. that's cool
  6. D3ATHF3YD's Avatar
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    Sep 11, 2010, 7:08 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #6

    Thanks, I just read up on it but couldn't find it in use on a project and with all of the info in one place. Figured I had the photos, so why not help more Fett's be born?
  7. D3ATHF3YD's Avatar
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    Sep 11, 2010, 7:47 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #7

    Hit a few bumps, but it's almost complete.

    Had a few air bubbles under the surface that I sanded into, I just widened them with a razorblade and filled with more Rondo mix. Easy cheesy, but my camera'sbatteries died and i figured anyone who's made it this far can repair a bubble with it by now. Here are some more pics:

    Also had to repair the lame ear flap, it warped slightly during the initial coat and went unnoticed until now. Had to hacksaw into it, push in a wedge and re bondo/fiberglass the sucker into position, you can see the somewhat corrected symmetry. it should get back to looking awesome as soon as I hit it with the ol' sandpaper, but my arm is tired right now and it'll wait until tomorrow.





    Thats pretty much it guys and gals! just keep going until your piece looks how you want it. Repair, trim, sand and paint. Thats all there is to "Rondo".
    Last edited by D3ATHF3YD; Sep 12, 2010 at 1:05 PM.
  8. Tovor's Avatar
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    Sep 16, 2010, 12:48 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #8

    Have you completed the helmet yet, and painted it? Interested in seeing the final appearance and coloring of it.
  9. D3ATHF3YD's Avatar
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    Oct 13, 2010, 6:24 PM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #9

    helmet still not finished yet, I sanded through into the hot glue joints and had to take a razor blade and cut below the glue then re-rondo the divots. Should have an update soon. going to go work on it more right now, finish sanding and paint is all it needs.
  10. mandosoldier's Avatar
    Member Since
    Jul 2007
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    Oct 14, 2010, 7:38 AM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #10

    what helmet is that? i don't recognize it.
  11. Member Since
    Oct 2010
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    27
    Oct 19, 2010, 10:23 AM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #11

    I realize this thread says extreme noobs, but what is the difficulty level if you have never done this? I have some basic model building experience from my youth, but have never used resin or anything..
    Also, I am confused on the whole Bondo, resin, fiberglass thing.. What's the difference? Is one better than the other?

    Thanks
  12. Member Since
    Sep 2010
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    Oct 20, 2010, 2:32 AM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #12

    Hi D3ATHF3YD,

    Great tutorial being new to the prop building I need to learn ways and methods used to craft my skills, not sure if you are aware but the helmets used in Tron are all old hockey helmets the model you have made here is the cooper sk2000 avalible at most used sports stores or thrift shops for very cheap the other models used in the movie are cooper sk600 and cooper xl7. you might have already known this just thought I would mention it if anyone else was thinking of doing a Tron helmet it would be an easier starting point, but you way looks like a lot more fun thanks for the help and tips!
  13. Rob Cooke's Avatar
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    Nov 2009
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    Mar 28, 2011, 5:59 AM - Re: Basic "Rondo" Tutorial for EXTREME N00BS (tron helmet) #13

    Hi,

    Many thanks for that as that's some really useful info. You also seem to have worked your way round the problem I am having which is why yours might be the best way to do things.

    I am consistently having problems with fetting Fibreglass/resin to conform around sharp radiuses. I've just built Dungbeetles Pepakura Fett Helmet and it has gone together really nicely. I am now looking are the re-enforcing side of things and don't want to mess it up.

    Any tips on how to fibreglass over 90 degree bends?

    Is there a feature on the forum that addresses this for a newbie to the fibreglass side of things?

    Best regards to all especially those in a similar boat.

    Rob Cooke

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