Bondo Body Filler w/ cream hardener
Bondo Fiberglass Resin w/ liquid hardener
Bondo Glazing spot putty
Bondo Fiberglass Cloth
Sanding paper (I used a sanding sponge)
Bondo spreader (I call them squegees)
Hot glue gun w/ Refills
Disposable Brush for resining
Laminating sheet (for visor)
(8) 5mm high brightness led's
(2) Jumbo Blue Led's
Vinyl clear tubes
Spray paints (I used Rust-oleum Rusty metal Primer, and gold)
(Spare Pants and jacket and
2 Leather Jackets (Thank god for Thrift Stores))
Also this build will require- Patience, Time, Basic wiring skills, and some experience or cautiousness with harsh chemicals.
Step 1: Making the Helmet
I also found some pepakura files which helped us with certain parts of the helmet.
We constructed it out of cardboard, and put it together with hot glue.
As for the detail parts, we had a lot of foam boards laying around and so we just looked at reference pictures and cut them out and also were glued to the helmet. (Black Parts)
Step 2: Resining
If you've worked with Resin before, then you should know that you have to be very cautious with it. It can be a big irritant to skin.'
If you don't know how to resin, there are many tutorials on youtube that are great!
So with a brush, mix the resin and the hardener just right according to your outside temperature, and begin the resin progress.
Step 3: Be Patient and Let It Dry.
Step 4: Reinforcing
So now cut the fiberglass cloth or mat into small pieces that will fit in the inside of the helmet.
Mix another batch of resin mix and now lay the clothe or mat inside the helmet and place the resin on top.
Again, there are many great tutorials on youtube that will show you how to resin the outside and inside of anything.
This guy's tutorials are great.
Step 5: Primer It!
Step 6: Sand It!
I wanted a more square-ish but still round look, so some parts are square-ish
Step 7: Bondoing
Mix and get your squegee out. be ready to work with it fast.
Step 8: Spread!
If this is your first time with Bondo, then don't stress it! Its bad to stress while working with it.
when you are done, give it 10 minutes to fully cure,
you can speed this up by leaving outside in the heat, and preferably in a sunny day.
Of course, its always hot in Florida, so that was not a problem for me, it cured really fast.
Step 9: Spot Putty, Primer, Paint, Weather
Spot putty was used to fill in imperfections.
The link which I posted on step 4 will show you how to do all of these steps.
Then I primered the helmet again, sanded it a little more, and finally painted it with the rust gold paint.
Red spray paint was also used to add a blood splatter effect to the suit.
And ta-da! The helmet is done.
Step 10: Armor Making
We designed all of the pieces without blueprints or plans, we just started doing it.
The armor plates were done out of foam, and with this foam we completed the backpack, front ribs, the chest piece, arm grips and gauntlet.
Step 11: Armoring
RIG was also done out of foam and all of the pieces were given industrial grade Velcro to hold pieces to the under armor.
Step 12: Painted and Weathered
These pieces were not resined.
Step 13: Under Armor
We started with the pants.
Both sleeves were ripped off the leather jacket and were fitted to the thigh region of the pants (Will be shown in later pictures)
They were sowed on.
As for the jacket, we cut leather pieces to fit the design of Isaac Clarke's RIG and they were also sowed.
and the hook side of the Velcro strips were attached to the underarmor.
Step 14: Lighting
And the same was done to the rear light.
Then I cut out a piece of the backpack to the Stasis meter I forgot to add before.... --_____--
But I think it came out fine ^_^
Step 15: Detaling
This is not necessary, but it adds on to the effect.
Step 16: Put It All Together! and YOU ARE DONEE!!!
Might not look perfect cause it is not made out of steel, and im still missing the boots and plasma cutter, but this turned out GREAT!
Don't forget to vote for the space challenge!
I wish I could have timestamped all the pictures but this build was finished on August 2, 2011.
Thank you for sitting through this Instructable.
If you do choose to make this build, private message me for any doubts or questions, I go on instructables pretty much daily, so I can guarantee a fast reply.
THANK YOU!!! :D