A good friend of mine who I will not name (and I would prefer you didn't name in this thread) was kind enough to send me a helmet to try my hand at. I have never really worked on a project as most of the props and pieces I have acquired are found parts so this has been quite the challenge. I am nearing completion and just couldn't wait to post pics.
The helmet is all fiberglass with a white gelcoat. when it arrived the entire visor section was solid so I colored it in with a marker, then quickly hotglued the ears and rangefinder in place just to get an overall feel for how the completed helmet might look. Here is the result:
I began the project by grinding down the raw bottom edge of the helmet and cutting out the visor section. Once the visor was removed I realized there were going to be some HUGE issues with sanding the visor lip and making it smooth. It is almost impossible to reach the inside of the horizontal slot of the visor with a dremel or sandpaper. Also I realized that some parts of the visor area were going to have to be built up with bondo, something I had never used before. Well, after MUCH bondoing and MUCh dremel work and more sanding than I even want to remember I am pretty much satisfied with the visor area. It isn't perfect but it is as close as I think I can get it.
At this stage I only have the cheeks and keyhole area to rework and I will be ready for my first coat of primer!
Here is the current state of the helmet:
Here are a couple of pics of the visor area so you can get an idea of what I have been doing. It doesn't look like much but it was a HUGE pain!
The helmet is all fiberglass with a white gelcoat. when it arrived the entire visor section was solid so I colored it in with a marker, then quickly hotglued the ears and rangefinder in place just to get an overall feel for how the completed helmet might look. Here is the result:
I began the project by grinding down the raw bottom edge of the helmet and cutting out the visor section. Once the visor was removed I realized there were going to be some HUGE issues with sanding the visor lip and making it smooth. It is almost impossible to reach the inside of the horizontal slot of the visor with a dremel or sandpaper. Also I realized that some parts of the visor area were going to have to be built up with bondo, something I had never used before. Well, after MUCH bondoing and MUCh dremel work and more sanding than I even want to remember I am pretty much satisfied with the visor area. It isn't perfect but it is as close as I think I can get it.
At this stage I only have the cheeks and keyhole area to rework and I will be ready for my first coat of primer!
Here is the current state of the helmet:
Here are a couple of pics of the visor area so you can get an idea of what I have been doing. It doesn't look like much but it was a HUGE pain!
, but, looks like you've done a great job on smoothing it out.
WOW!! That looks really great Braks! You should be proud! I don't have a fiberglass helmet (not yet) 
, but I did make my own gauntlets out of fiberglass. Even a perfect original, with a perfect mold, perfectly cast will need some finishing. Making the helmet flush to the visor right out of the mold is impossible. The outside of any fiberglass piece is all smooth and pretty, but the other side will have some variation in thickness of both the gelcoat and the layers of fiberglass. A few layers of bondo and sanding will fix it right up. The gelcoat is very tough and needs to be sanded down with a course, then medium, and finally fine grit sandpaper before primed. This will make the surface perfect for wetsanding and then painting. 
