I almost made some progress this weekend, but not really. Shawn was good enough to have his CNC machine, known as Lopez, cut me out some chest armor. All said and done, it looked really good, but we made it too small...
On a good note, My friend Colin was able too put a few hours in and we cast another helmet. I've been asked to explain the roto-casting process a bit, so I made it a point to get some pictures to help explain if other people were interested in the process as well.
![photo(18).JPG photo(18).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46653-ddba4fc3e6d95fd3eae19871d0571ff6.jpg)
Chest armor looks pretty good.
![photo(19).JPG photo(19).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46654-60fc47d08c598b4fc8f0c68302e13446.jpg)
...but maybe a bit small...
![photo(16).JPG photo(16).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46649-4a33a60d00fb4b6ab3192ef70d4d30e1.jpg)
When we roto-cast, we pour the resin into the helmet mold.
![photo(17).JPG photo(17).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46650-2262e2cb1177f8c90e78d2b6c7783f47.jpg)
Often we will put the mixing tool into the mold and pour the resin onto the mixer while it is spinning to help cover the sides of the mold. Care should be taken if you do this as you can easily get resin all over your clothes, the floor, ceiling, walls, dog....
![photo(15).JPG photo(15).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46651-736829a9e3a7a3ab9d13d7849fb6bde1.jpg)
We then pick up the mold and rotate it in every direction to allow the resin to cover all the surfaces, then we repeat...
The first coat of resin is straight resin and is used as a print coat to get all the details. Once this layer begins to thicken up, we place the mold open side down to allow the resin to drip down and thicken up around the neck hole. The next two coats of resin are done the same way, but a filler is added to thicken up the resin; this coats more evenly and helps add thickness. The last coat is again just straight resin.
On a good note, My friend Colin was able too put a few hours in and we cast another helmet. I've been asked to explain the roto-casting process a bit, so I made it a point to get some pictures to help explain if other people were interested in the process as well.
![photo(18).JPG photo(18).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46653-ddba4fc3e6d95fd3eae19871d0571ff6.jpg)
Chest armor looks pretty good.
![photo(19).JPG photo(19).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46654-60fc47d08c598b4fc8f0c68302e13446.jpg)
...but maybe a bit small...
![photo(16).JPG photo(16).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46649-4a33a60d00fb4b6ab3192ef70d4d30e1.jpg)
When we roto-cast, we pour the resin into the helmet mold.
![photo(17).JPG photo(17).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46650-2262e2cb1177f8c90e78d2b6c7783f47.jpg)
Often we will put the mixing tool into the mold and pour the resin onto the mixer while it is spinning to help cover the sides of the mold. Care should be taken if you do this as you can easily get resin all over your clothes, the floor, ceiling, walls, dog....
![photo(15).JPG photo(15).JPG](https://thedentedhelmet-f28a.kxcdn.com/forums/data/attachments/46/46651-736829a9e3a7a3ab9d13d7849fb6bde1.jpg)
We then pick up the mold and rotate it in every direction to allow the resin to cover all the surfaces, then we repeat...
The first coat of resin is straight resin and is used as a print coat to get all the details. Once this layer begins to thicken up, we place the mold open side down to allow the resin to drip down and thicken up around the neck hole. The next two coats of resin are done the same way, but a filler is added to thicken up the resin; this coats more evenly and helps add thickness. The last coat is again just straight resin.
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