At this point, I was pretty happy with the helmet overall. There were minor things that could have been better, and even now, I see things that bug me, but I found that I came to a point of diminishing return, where the more work I did, the less it mattered overall, and the more frustrated I became... So I moved onto molding, which was my focus from the start. I opted to use Rebound-25 as I have for small projects in the past. I've also used DragonSkin, but thought that rebound may be a better fit for this helmet. Here we go...
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So it begins...
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Started to add a thickening agent to fill in deep voids.
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Added keys for the mould jacket
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Opted for a fiberglass 2-part mother mold because it's inexpensive and also I've done it before, so it was familiar for me.
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Original, first cast, second cast. Used Smooth cast 300 for these first few, but then moved to 65d after talking to the folks at smooth on about my project.
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Scoring the inside of the earcaps and helmet for better adhesion via two part five minute apoxy.
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More photos to come on the painting process.
