I call it v3.0 because what follows is my third attempt to build this helmet. The v1.0 was last year. Then v2.0 basically self destructed and I had to start over. So this brought me to v3.0.
Now last year, it took me around 9 months to build this helmet. This year, I did it in a month and a half.
I had some criteria for this build to improve over last year.
1) Stronger
2) Lighter
3) More accurate in scale
Optionally, I wanted it to be cooler too.
For v3.0, I started with some very familiar materials to use as the skeleton: cardboard and paper.
The cardboard was glued around a hard hat. The hat helped me keep scale and makes this very comfortable to wear.
Paper was then glued over the cardboard to give me an even skin surface for the next step.
Last year the next step was paper mache, but that takes way too long, is not sturdy and not as light as you would think.
My tools for this year are fiberglass. Not just the resin, but the matting too.
This was then effect of the fiberglass. It is very sturdy at this point and light as a feather. It needs a lot of sanding, though.
Sanding is done. Now to the Bondo.
I used the Bondo to build up the surface and smooth it out even more. I knew I was going to need a lot.
Standard can of Bondo on top of a 3 pound can of Bondo. They’re both gone now.
Naturally when I started this, it got cloudy and started to rain, so off to the basement.
The lighting here makes it look like it is covered with butter cream frosting. It’s not. Now for more sanding.
Smoother. Now we prime it. I prime it here so that I can get an even single color and be able to see what the surface really looks like and know where to fix.
Now for some more Bondo and sanding and priming.
Yup. Different color primer. This is actually a high fill or gap filling primer. Works great.
Now I need to start thinking about the face glass, lights, and rivets.
Last year the lights I used in the face came out really orange instead of yellow. This year I dismantled some LED flashlights I got on clearance to use for the lights. The flashlights had a long lamp like section and a standard spot light section. Lamps for the face and spots for the chest. To color the face lights from white to yellow a piece of yellow party napkin worked for a great filter.
Hey, the blog isn’t called The Real Redneck Geek for nothing.
All the lights in and working.
Quick size comparison from last years build.
Face glass and rivets in place and everything masked for one last primer coat. Rivets are the same wooden plugs I used last year. The orange bit on top is for the camera. It’s actually the lid off a Gatorade bottle.
It’s ready for paint now.
The “hammered” effect didn’t come through as well this year. They must have changed the formula.
Shiny and new like it just came off the assembly line. That’s not going to work. It needs distressing.
Center of the mask also got tinted like last year and then I used shoe polish to add the black smudges. Then I dry brushed on some green paint to look like corrosion.
All lit up. The lights in the face actually remind me of the helmets from the original Battle Star Gallactica.
The dive weight is cut from foam and then colored with shoe polish.
I was also able to accomplish my optional goal of making it cooler. Last year I had 4 fans in the helmet and they just couldn’t move enough air. This year I bought this:
The Vantec Tornado Case Fan. with airflow levels as high as 85 CFM. It is a little loud, but not that bad and the payoff is a nice cool breeze in my face the whole time.
Gorilla tape, hot glue and cardboard make a good fan mount.
Two switches for the lights and fan. All the batteries and wires are under the fan mount. That’s when I realized, I may need to change those. Quick use of the box cutter and:
Peel this open, and there are the batteries and wires for if I need them.
So, from 9 months last year to 45 days to build this. All criteria have been met and honestly I am really proud of this build. I know it is not perfect, but for a quick last minute decision to build this, I think it’s great, and I have a feeling my two biggest fans will like it.
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