Hey Skip!
Thanks for the ideas! I do indeed have a mouse(ish) sander and looking over your post - things might not be as bad as I think... Ive attached pics below to explain my problems... hope this is ok with everyone?
Also PLEASE NOTE - these issues are with the fact this is my very very first full build and nothing to knock about the excellent templates!
OK so on with the state of the union: I gave this a quick coat of grey primer to make things a bit more uniform...
Firstly a general look - I think my issues arise from the fact that I put the complete template together, forgetting about the closed off areas that need fiberglassig BEFORE being attached to the helmet:
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Secondly - the circled areas are parts where the air bubbles/unset fiberglass is causing warping. The arrow is to the area I'll have to remove as the top visor and 'snout' have no glassing support inside at all:
You might notice the colour change at the back of the neck... I started with Fiberglass cloth (darker) and changed to Fiberglass cotton - its easier to work with but I feel it caused some of the problems Im having with trapped air...
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Third - The ear will have to come off as above, there is no support! Doh! The back of the head, has air bubbles so moves to the touch:
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Fourth - Just a top view. Im not sure if it came out in the pic but as Skip said Some areas are down to almost the bare card - I think this top part is ok?
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Next is just a back view. One side of the upper part is bondoed the one without the arrow has none. You might be able to see the arrow area is lower (and correct) while the opposite side is higher as it warped without fiberglass support:
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On to - Other side. The unbondoed area needs Fiberglass reinforcing and the ear has to come off:
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And finally, all the issues together. Working from the top - The top 'visor' part has no glass underneath so I might just remove that and re-do it. The actual area you look out is fine, just needs bondo. The unbondo'd side should be fine with more FG. Might just cut off the entire front as its just paper and the bottom rim parts should be ok to straighten with careful FG work...
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Ugly SlideShow
So what do you guys think? Looking again, Im not as sure as I was that it is a writeoff...
Anyhoo - Thank you all for the comments... again I cant express how much of a fantastic learning experience this is. As long as I can learn form my mistakes Im a happy bunny
Thanks folks!
Dave