Thinking back to my stormtrooper helmet and all the fans, batteries and microphone electronics I needed, I figured I would need an extra inch of space. I cut small rectangles of wood an inch long and used them as spacers between the two halves. I taped them in place and used clamps to make sure the helmet didn't shift. Added a thin layer of resin and fiberglass to the inside.
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Well guess what, the helmet shifted. I cut the new fiberglass only down the right side and put a small shim until the strip behind the ear lined up.
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Sanded the resin and put a chamfer on the helmet edges, hopefully to help with the bondo covering the edges.
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And the first of what I suspect to many layers of body filler.
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An early christmas miracle, my pack from [USER=2367]Darth Voorhees[/USER] arrived and also bought a helmet from him. I've been working 75+ hours lately at my job but I'll get it started soon when I have time off. Plus we had a huge winter storm last weekend and a pine tree crashed in front of my garage that I'll need to take care of.
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Stay safe, happy holidays.
