Yet another ToEleven scratch build

I've been tweaking this thing endlessly...getting closer to the finish line.


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Ear platforms, turn signals & Ears.


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I have a little sanding and tweaking left, but this is about 90% there.



























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That is looking fantastic! I'm also impressed by how quickly you've made such progress, though if this really is your fourth build, I suppose it's no surprise you'd be a Jedi Master at scratchbuilding by now. Awesome job!
 
Thanks guys! That dent has been a big time sink for me just to get it right.

I figured I would share a little of my process at this point.

side view comp.jpg
Here we have some problems with the left cheek and brow profile... I set up a photoshop comparison.

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I glued on a template built it out with bondo. Yes, that is a pink slipper there. Someone was "helping" me.:lol:


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Got my ears resin coated, sanded & primed. I had a local guy 3d print these. I've already had to modify once...I may need to again. My own fault for not double checking measurements.:facepalm
 
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Great idea on the cheek fix, what happened to the CNC ear pieces?

I had issues with the mdf being a bit to soft on the pointy part at the bottom, and they were too fragile. I was going to machine the bottoms separately, but I found an inexpensive source for 3d prints which turned out to be pretty nice. 3dhubs.com will show you people near your location who can 3d print. I got connected to a local guy in my city who offers his services.
 
Thanks again for the compliments.

My dent started life as a basic angular shape that you see on most scratch builds. One thing I notice is that most dents are too deep and often conical in shape. So I thinned some bondo with resin and let some pool up in the bottom so could sculpt down into it.

The Rafalfett template is a good start for the outline/edge, but I found that it has a few details that didn't line up with photos. The top/left has a couple extra dips and bumps that I can't see. Additionally The dent is a bit more extended (by a millimeterish) at the left side points...you just can't see it because most photos capture it from a front/right to front angle. I first noticed this in this photo of the GMH. Dents are also apparently like snowflakes...no 2 are alike. They all appear to be the same until you see them side by side. We know the casting process produced slightly unique shapes from what we see in the differences among the various screen/production used lids.
Dents.jpg

I also put together side by side pics with my dent taken at similar angles to get a better view.


The rest is trial and error. Here are some of the various tools I'm using to lay bondo and sculpt with. Modified coffee stirrer that I swear I didn't take from Starbucks/Fivebucks, sanding sticks from the model car section at Hobby Lobby, various craft sticks with sandpaper spray-glued on, tiny file set, cheapo artist spatula set for bondo sculpting, tiny pieces of 120-180 grit sandpaper.
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For the bondo sculpting you need some acetone to dip your tools in so the bondo won't stick. This will let you spread and push it around easier.

If you look closely at the dent, it is really more of a bowl shape...none of the valley lines go straight down to a center point....they all have a slight curve...some are sharper than others, etc.

This is where I am right now with mine. Apologies for the lighting.
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Lots of good information here, thanks for sharing. I really think this is definitely your best build yet, congrats!
If you do decide to go through molding and casting, please post your process. I haven't seen a post about molding helmets on TDH yet and we could use a sticky on the front page.
 
Lots of good information here, thanks for sharing. I really think this is definitely your best build yet, congrats!
If you do decide to go through molding and casting, please post your process. I haven't seen a post about molding helmets on TDH yet and we could use a sticky on the front page.

That's a good idea. I may do that if it doesn't crash and burn lol. Seriously though, I'll document it and post something for sure.
 
For anyone else trying to sculpt here are some of the composites I'm using with my helmet...to give you an example of what you can do with gallery photos.

right side comp 2.jpgright front.jpgProfile right.jpgside view comp.jpg
 
My silicone has arrived so I did my last bit of tweaking before I start working on the mold...hopefully I can get most of it done this weekend.

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...and I ran these guys on the cnc. 1/4" aluminum flat stock.
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