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Step 17: Chapter 3- Helmet Molding 1: Preparation and Clay Walls


Tools and Materials
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We now begin the process of making the mold from which you pull a light-weight wearable cast.

The shape of your model will determine the complexity of your mold.  The simple shapes that we've made so far were easily replicated with simple, 1-part molds.  A shape as complex as your helmet would be impossible to replicate with a single mold.  You could coat the entire helmet in a thick coat of silicone but then you'd never be able to remove the model without destroying the mold and you could never pull cast from it either.  In this instance, it will require a 3-piece set that consists of a mold of the front, a mold of the back, and a mold of the bottom.  The molds are intended to join where they can part most easily from the original model and subsequent casts.  You can find many videos on Youtube that elaborate on the basics of mold making if you need more information.  I am only going to focus on the specifics of molding this particular project.

We begin by creating the parting wall that divides the front from the back and the bottom.  I determined that the ear-line and the "lower jaw" were the best places to build a dividing wall of Klean Klay.  This dividing wall prevents the silicone from leaking into the areas we want to keep free of rubber.  You'll want to create "key shapes" in your clay.  These shapes will allow the different parts of your mold to register with one another and interlock.  In this instance, I used a long, narrow strip of clay and some simple wood pegs I had lying around. 

Build up the sides of the dividing wall to keep the silicone from spilling over the edge of the dividing wall.  Now you're ready to mix and apply the silicone.


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<p>Has anyone actually tried to make this?</p>
<p>This is one of the most amazing process I have ever seen! This instructable teach a lot of thing, at the same time its POWER ARMOR HELMET man! (=</p>
Staggering. Just... I'm nearly speechless. I'm stunned by both the incredible piece of genuine art you produced and by the detail, clarity, and understandable description of the work that you provided. Bravo. I'm in awe.
<p>Error 404- Comment not found for sheer happiness of what I just saw</p>
<p>my son is a massive fan of fallout games would love to buy one if your selling</p>
*cries with happiness and creates a river of eternal joy* sorry. :P. I &lt;3 fallout. Favourited. I'm only 14 but one day I have to build this :)
<p>???no comment blown away</p>
<p>I was wondering what specific product you used for the gel, how much was needed and how much it cost. I really like this concept as an alternative to fiberglass and bondo and I am planning to try it out myself.</p>
<p>Awesome work!! Thanks for chairing!</p><p>I want to start the project, but the fact that the files from the links you chaired come with viruses is annoying me...</p><p>I don't want to open the files given this, so I'm kind of stuck...</p><p>Is there any other place where I can get those files?</p><p>Thank you</p>
<p>This is Awesome!</p>
<p>Unless I am doing something wrong it appears that the PEP file is no longer available on 4Shared.</p>
<p>Nevermind. I located it. Once you hit the small Download button (Small white/gray button) You have to hit the &quot;Free Download button on the next page to start the countdown. After the countdown the file will download.</p>
<p>Awesome, it makes me wonder how much a real stainless steel casting would set me back. You made such quality moldings ... at least it looks to me that way.</p>
You are flipping amazing!
<p>I'm building my own helmet at the moment - the mould lol i dont have the money neither access to some of the products. I cant for the life of me find the big rubber tubes you used on yours. Could you please tell me what tubes you used and maybe where you got it from? thanks :)</p>
<p>it almost gives you the idea of the gaiters on a motorcycle however thats very expensive and far too short. I'm close to surrendering and using pool piping but it struggles to get the bend and look i need. some rubber ducting pipes are similar to yours and gets a better bend than pool pipes maybe i can find some off-cuts somewhere.</p>
<p>I know this post is 10 months old but I had the same issue. What you want to find are WW2 Czech gas masks, also labeled under ww2 russian gas masks. They also sell the hoses themselves on Ebay from time to time but the cost is similar to just buying the whole WW2 mask, expect to pay around $10-20 a hose.</p>
Hey thanks for sharing the pep model you created. This is the first of several fallout props of plan to make. Next on my list I'd planning the tesla armor patterns. I'm a bit of a larger guy so modifying the model into wearable patterns is going to be a challenge.
Can you please email me at billyjbrixey@Gmail.com
<p>Thank you so much for taking the time and effort to post your work! You saved me a ton of grief on my build! Here is to Fallout 4....</p>
<p>Make another one and sell it to me! I'll work up the money! How much to you want for it????</p>
<p>DAMN the Russians!</p>
<p>how to scale prepakura model to my head dimension ?</p>
So beautiful. So wonderful.
<p>Really enjoyed your post. Would like to learn more about how to use the file you provided and the software. I found both of them but am struggling how to make them work. </p>
<p>This is awesome, thanks for sharing your excellent work with us.</p>
<p>It's absolutely amazing, I wish I had your skills!</p>
Man! You work is FU#$&amp;%* PERFECT !!! almost cry when I saw...AHIUAEHSIEHaishE <br> <br>Perfect, really...
THIS IS AWESOME!!!!
Hay Man, Amazing Work, Fallout 3 is my all time favorite game and i feel &quot;required&quot; to try my hand at crafting one of these things! I have gone through the tutorial and and added everything i think i will need for the project into my amazon cart and i guess my big concern is the amount! you never really specify on a what a good amount of a given material should be purchased. Is there any way you could add a list in the beginning of your guide with an approximate estimation on each material for one complete helmet! <br>Thanks for your time and work!
awesome work. <br>
no no good work thank you
your link doesn't work
In this way, the body and the legs do I create? <br> <br>We want to hear from you
Did you measure the circumference of the head in any way?
Do you think you can email me the helmet base if possible.
dude <br>freakin awsome
can i just buy one from you?
Wow! Some day, I'm going to make this and never take it off.
<br>bos_helmet.pdo <br> <br>this is all i get it won't download like the file is gone !
Congratulations on being a finalist in the Halloween contest!!! Can&rsquo;t wait to see if you win! Good luck!
I absolutely love this mask! It's incredible how much detail you put into this.
Great Job, were you planning on ever seling one of these??
Ok Thanks. Like i said my helmet paper model is too flimsy and i guess i wont be able to do something with it. Its not looking like your model mine is more round. =/
what thickness of card stock did you use because i used a card stock that was too thin and now i have to re-do all the paper helmet model. <br> <br>Thanks, <br> <br>P.S.: Nice instructable :p
I'm not sure which brand of card stock it was. I went to Fed Office/Kinkos and picked out a card stock from the selection they had the counter.
Hi Josh, <br>It is Realllllllllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyy <br>ROCKINGGGGGGGGGGGGGGG G G G G GG G G <br> <br>great job done man. <br>

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Bio: I am a video game environment designer by day. I am a prop builder by night.
More by Josh Jay:The "Highwayman Inn" (from Sketchup and 3DS to Reality) The Engagement Box (from 3DS and ZBrush to Reality) Fallout 3- Brotherhood of Steel Helmet 
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