Step 11: Resin casting & trimming

To make a copy of your helmet with urethane plastic, you'll use a process called "slush casting"

The video below is pretty dry, but it gets the general point across. Skip to about 4:20 to get the the relevant information, though there are some good tips about mold prep beforehand as well.

For my helmets, I use Smooth-On's 300 or 320 urethane casting resins. Start by mixing 2 cups of resin (1 cup of part A mixed with 1 cup of part B) and pour it into the mold cavity, rotating it slowly by hand as the resin cures.

Repeat this process, moving the mold around to cover all areas of the inside of the helmet, until a uniform thickness of 3/16" is achieved. If some spots are a little thicker, that's fine; slushcasting is a tricky process that can take some getting used to. One helmet usually takes about 32oz of resin.

Warning! I did castings in both polyester and urethane resin - the poly is lighter and thinner, but more brittle. Urethane can deform and its heavier, but much more forgiving when subjected to stress. Whichever resin you choose to go with, read the MSDS (material safety data sheet) and make sure to use a resin that can stand at least 140º of heat. Shipping a helmet in the summer to a chrome shop can subject it to 120º+ in a shipping truck, and the chroming process itself can be quite warm as well. Some resins, like Smooth-On's 65D Roto resin, have lower melting temp and can deform very easily.

After the helmet is fully cured, remove it from the mold and trim out the areas for the visor, ears, mouth and nose vents using a dremel tool and hand files. (pics 3 & 4)

Materials needed:Tools & supplies needed:
  • Disposable mixing trowels
  • Mixing cups
  • Sandpaper
  • Detail files
  • Dremel tool
  • Cutoff wheel for dremel tool
  • Sanding drum for dremel tool
  • Rubber gloves & smock
<p>What's The Total Cost To Build It</p>
how do you see through it?
<p>There appears to be gaps between the LED's and since the visor is transparent it allows you to see through it in brightly illuminated areas, however as the article mentions if the LED's are turned on in a dark area you wont be able to see at all.</p>
<p>You could probably use surface mount LED's to put them right up against the visor so that no light goes back into the helmet if you wanted to see at night, however you would not get the same domed LED look.</p>
Can I pay 100 dollars for you to build it
<p>I would suggest asking around locally or looking up to see if your city has a maker space or hacker space, I'm sure if you bought all the materials you could pay someone around that much for them to build it.</p>
<p>They cost 25k for a complete one.... </p>
<p>do you sell or offer a pre assembled visor kit, or know where one can be acquired for those with little electronics experience?</p>
<p>Having a kit this specialized would be pretty expensive, I would advise just getting a couple of addressable LED light strips and cutting them to the correct length and using an arduino board or something similar to control them.</p><p>You would still have to solder stuff but it would not take nearly as long and finding someone to help you program it will not be hard, it would only take me about 5 minutes to write a program to control such a display with simple animations or text.</p>
<p>Although since LED strips are surface mount (or in otherwords instead of the lights being dome shaped they would be more flat) you would not get exactly the same look, but it would still look good as well as the fact that you could get an RGB strip (a led strip with red, green, and blue LEDs in each diode) and have a multi colored display.</p>
<p><strong>For the silicone Rebound 25 do you think I could get away with just using 2 of the trial kit or would I need the full gallon kit?!</strong></p><p><strong><br></strong></p><p>http://www.smooth-on.com/Rebound%3D-Self-Th/c1132/index.html?catdepth=1</p>
<p>why is it punk?? </p><p>Looks like a startrek/pick a sci-fi helmut, but not punk.</p><p>It is quite awesome though!</p>
<p>daft punk is the name of the musician. </p>
<p>AHA, </p><p>I see, I could not imagine how that was &quot;punk&quot; then I did as two suggested and followed tghe links, plus I wiki'd it. The outfit was a gimmick to sell music. Well it worked for KISS why not someone else. </p><p>great work making the thing, but pointless unless you are making a movie, or going to a party, (for a while anyway). I carve and have made quite a number of useless pieces. Chach-ki's (Yiddish for dust collectors)</p><p>Again, wonderfully done</p><p>thanks</p>
<p>But the reason that they wear the helmets was to remain anonymous and be recognized for their music.</p>
<p><a href="https://en.wikipedia.org/wiki/Daft_Punk">https://en.wikipedia.org/wiki/Daft_Punk</a></p>
<p>Thank you for all the insight on this build. Building this from scratch was very fulfilling,....tough but sooo worth it! Guy Man is next :)</p>
<p>Hi, what an excellent instructable! A mix of electronics and props... A lot of hard work has clearly gone into this project. </p><p>Karl</p>
<p>In oddly crazed digression - say you were to do this for the head/face of a friend and make a mask of them and sneak into a pumpkin patch early in the season and have the pumpkin grow into the mask. Remove the mask and you have the face of your friend as a freak of nature.</p>
<p>I'm speechless now! :D Awesome!</p>
<p>What a craftsmanship! This is incredible! Congratulations on it. Maybe I will try it one day. Just astonishing!</p>
<p>Now I just need the dietary supplements to get my head inside comfortably :) Some kind of phat burner.</p>
<p>How much did it cost to chrome your helmet?</p>
<p>I have the same question. Spray painting with &quot;chrome&quot; paint is not the same as chroming.</p>
<p>Well Mathew, you can get the chrome paint at your local AutoZone for around 10 to 20 bucks.</p>
<p>I wish I had received this email 4 months ago lol. I just bought a Thomas one off eBay and a Guy one from Etsy</p>
<p>though I should add these were premade molds that may not fit my head and there's no LEDs.. I wish I had the right money to blow on Volpin's products</p>
<p>Have you had anyone buy one from you yet, volpin? I wish I had the money.</p>
<p>Can you see out of this?</p>
<p>Greatly detailed work, I wish I had the skills to do this project. Do you sell them? If so how much.?</p>
<p>He takes 25k for a fully finished one.</p><p>See my more detailed answer to lukesjette.</p>
<p>oh...WOW! I wish I could afford it, my son would love it. He's been asking me for a daft punk helmet. Again GREAT JOB! Thanks for the reply . </p>
<p>r they for sale</p>
<p>Completely finished one is 25k. Yeah, no joke there. It takes a long time to make one, and the parts and electronics used are really expensive.</p><p>Plus, Harrison Krix (aka Volpin Props) is a professional and likes (also deserves) a good hourly wage.</p><p>Don't believe me? Check out his shop:</p><p><a href="http://www.volpinprops.com/product/completely-finished-daft-punk-helmet-replica/" rel="nofollow">http://www.volpinprops.com/product/completely-finished-daft-punk-helmet-replica/</a></p><p>You can get the slush-cast resin base for much, much less but it's still in the triple digits. Or the blueprints for making your own one for a fiver.</p><p><a href="http://www.volpinprops.com/shop/" rel="nofollow">http://www.volpinprops.com/shop/</a></p><p></p>
Oh that's a bit much for me ?
<p>Excellent Instructable Job!!!</p>
<p>Excellent Instructable. You are truly a dedicated and talented craftsman. Thanks.</p>
<p>WOW! Almost too cool to be true ;)</p>
<p>Wow, totally amazing and artistic work.</p>
<p>Harrison! I saw you on tested!</p>
<p>This is really brilliant! favorited!</p>
<p>This is truly incredible! One of the best helmet I ever seen :o</p>
<p>The word Awesome was invented for things like this!</p>
Can you use plexiglass for the visor and still dye it the same way?
<p>That is just ridicuously awesome!</p>
<p>name your price volpin.....</p>
<p>Around $3000</p>
lol dude i could buy like 5000 tickets of his show with that much.<br>I know u r trollin wid me
<p>I guarantee you cant buy a ticket for $1.66 and he's not dude: http://www.ebay.com/itm/Daft-Punk-Full-Led-Gold-Chrome-Helmet-Includes-Gloves-Necklace-And-Stand-/191424388473?pt=LH_DefaultDomain_0&amp;hash=item2c91c85d79</p>

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More by volpin:Building a Small Format Vacuumformer from an Old Toaster Oven Creating Costume Armor with Wonderflex Creating Helmets and Armor from Videogames for Fun and Profit! 
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