Okay, here goes. I started with the templates from WoF and printed them on heavy stock paper. I purchased a lot of materials, Bondo, Fiberglass, X-Acto Knife, 1/4" foam board, Super Glue, etc. etc. I cut out the templates I needed to start the helmet first. Let me just say, I have heard it before on this site and it is true, building your own helmet is rewarding and a lot of fun!
So, after I had my templates, I basically began with the dome pieces and trimmed those out with the X-Acto knife for precision pieces. I formed the dome and used tape to keep it together (which was quite a challenge). Now, to explore all avenues, I took my completed paper dome to multiple stores to try and find a helmet of some type to match the prototype as exact as I could find. I was able to find one for $20. at Toys R Us and have yet to take some pictures (sorry). I am only keeping this as a back-up in case I cannot duplicate or fabricate the dome using my paper template. If anyone has any suggestions on how to go from paper and tape to Bondo and Fiberglass, I would love to hear it. My thought was to take the dome as is and layer on some fiber resin on top and then underneath, maybe a little Bondo here and there and then sand it to perfection. Suggestions? Thoughts?
Next, once I got back home, my kids had expressed disapointment in not purchasing the Hanna Montanna bike helmet (I explained to them what I was going to do with it, and they wanted me to purchase her helmet so that I could - or they could - DESTROY it, with pleasured faces!). Anyway, I took my paper templates and layed them out over my 12" x 48" piece of 2mm Sintra (purchased in two sheets of 4' x 4" each). I then took the X-Acto blade and cut-out, VERY CAREFULLY, the first outer layer of the helmet.
That is where I am at for now, only the really fun stuff next!! Can't wait. Anyone with ideas or input on the Fiber/Bondo idea would be great. Plus, if anyone has taken their completed dome and made a silcone/rubber mold and cast a dome, I would love feedback as eventually, that is what I would like to do.
Eric