Making a dwarf welding helmet out of fiberglass.
I've been thinking about a new project lately. And for that I need a lot of tips. So here is what, why and how.
I'm currently making a welding helmet out of an old beer keg as in the instructable of bricobart. When I started with it I though about using the keg as sheet material to make a papercraft mask, probably Dr. Doom or the ABC warrior Hammerstein from the first Judge Dredd movie. I quickly realised it wouldn't provide me the result I like to have, so now I'm just making the 'simple' version from bricobart.
But I don't give up that easily. I also want to make something out of fiberglass and epoxy resin for a while, just to have the experience and to try it. So my quest for the perfect helmet/mask continued. I found Fallout helmets, which have tubing on which I could attach a breathing device. But finally I came to this Erebor helmet from the Hobbit.
The plan is to make the Erebor helmet with a hinged visor. I am planning on using several pepakura helmet models and combine them to make the helmet suitable for my welding purpose. The hinged visor and all other mechanics like that I can work out myself. The paper helmet will then be covered with epoxy and fiberglass as can be seen in several other instructables. To make it smooth and for details, I will use car body filler. (I already know EVA foam is the better choice for the helmet, but I don't trust is with the temperature of the welding and I read things about epoxy resins not werking properly on EVA foam.)
However, I never used epoxy resin/fiberglass/car body filler or any of these kind of materials. So therefor I need al the help I can get from here. What kind of stuff is suitable for my welding helmet due to high temperature (gradient)? What is the best way to go so all parts will connect properly? Is it wise to start this project?(Please don't answer no, because I will probably won't listen). Painting tips, epoxy tips, general tips etc.
Thanks in advance.