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Back in 2012 before I knew as much as I know now and before I knew Worbla existed-- I modified a helmet for a Celty Sturluson of Durarara!! Cosplay.
What you'll need:
1. Helmet to use as a base OR make your own!
2. Painters Tape
3. Lightweight cardboard or tagboard
5. Sand paper
6. Paper Clay or air-drying clay
8. Yellow and Blue spraypaint
9. Crystal Clear Enamel spraypaint
Step 1: Step 1: Prep
1. Order/buy/obtain/thrift a helmet for the base
2. Take off the visor and tape off parts you don't want to muck up
3. Make sure the helmet is clean and dry before beginning
Step 2: Step 2: Form the Ears
Using tag-board and painters tape, form the ears and tape them to the helmet.
To get them the same size, make a pattern out of regular paper first.
Step 3: Step 3: Prep Your Helmet
1. If your helmet is shiny-- sand all of it off.
2. use Gesso to to prime the helmet and give us a nice base to work the paper clay on
3. wait for it to dry, and then prime again.
4. sand the helmet once dry-- and dust it off.
Step 4: Step 4: Sculpt Up the Ears
1. use paper clay or an air-drying clay to build up the ears.
2. Make sure to sculpt from the ears onto the helmet for added strength.
3. Get everything as smooth as possible and allow to fully dry
4. You can also use the paper clay to hide any imperfections in the helmet base that don't match the cosplay.
Step 5: Step 5: Prep for Paint
1. Once dry, sand everything smooth
2. If you're having difficulties getting everything smooth at this stage, you can try using Wood Filler
3. once sanded smooth and dusted-- apply a coat of woodglue to the entire helmet. This will help for added smoothness and added strength
4. optional to add another layer of woodglue after that coat has dried!
Step 6: Step 6: Base Coat
1. spray paint your helmet yellow in light even passes
2. Wait to dry
3. sand with a less abrasive sandpaper in delicate circles
4. Dust off
5. Evenly coat with another layer of yellow
6. Wait to dry
if it looks nice-- move onto step 7! if not, Continue spraying, drying, sanding until you're satisfied.
Step 7: Step 7: Blue Details
1. use your painters tape again and mark off the places that you want to protect from the blue
2. Spray on your blue in nice even passes with the spray paint
3. I personally didn't need to apply another coat-- but if yours looks lame then follow the same process you learned from step 6 and make it look GOOD! :D
Step 8: Step 8: Draw on Designs
I hand painted on this front design but if you want to-- you could tape off this design or create a stencil. I personally just found it easier to match the blue color from the back and hand-paint this on!
I also sprayed the sides of the visor and then hand-painted the "V" design.
Step 9: FINAL STEP: Seal the Deal
Use coats of crystal clear enamel to protect your paintjob!
Slap that visor back on and YOU'RE DONE! :)