Introduction: Fallout 3 T-45d Helmet

Picture of Fallout 3 T-45d Helmet

Hello, before I start, yes it's another helmet, I can't help it! I'm addicted! But after this I'm getting help, hopefully with the intervention I might be able to make something else for a while, like I don't know, armor or I really want to do some more wood work , but it's still bloody cold here, anyways I'm not sure, but I do know this, this helmet was a great deal of fun to do , it's another pepakura file, but it was a very basic file, the rest of the lid was made with found parts and making parts, lots of people cast there work then go from there, I don't cast, I make one offs, I think casting is fantastic, but I just don't have the time or money or space, maybe one day,
Without further a do, I present, my addiction, my muse,another bloody helmet.......

Step 1: Pepakura File Beginnings

Picture of Pepakura File Beginnings

Unfortunately I didn't take many actual making shots, most of the shots here will be static "head" shots, apologies, to be honest I got the pep finished and thought I wouldn't get much further, it was very basic I didn't see the point, but then I found some bits I thought would work, and I decided I'll fiberglass it and bondo it and see where it goes

Step 2: Bondo and Sanding

Picture of Bondo and Sanding

As before many times, after fiberglass I bondo, this part takes time, I put real thin layers on, sanding as I go and I started a new thing, I'll sand and get the bit I'm working into a good shape, then I'll spray it with any colour it's not important, what is important is looking for low points or bits that look wrong, the paint is unforgiving so it's easier to see

Step 3: More Bondo and Sanding

Picture of More Bondo and Sanding

More bondo and shaping, all theses steps are basically sanding and looking at your work, what looks right and so on,

Step 4: Planning Out

Picture of Planning Out

Ok so skipping the days of sanding, we come to planning out, I've got the lid into some form of shape I like, I like to plan out what's what, helps me see the final thing and get my head around where to start and what I want etc, again not thinking to much about finishing it, more just the practice and trying to use real world parts and seeing where I end up

Step 5: Some Detailing

Picture of Some Detailing

Ok so I'm this far in, might as well stick some detail in and see what happens, I ise stuff called multiput, it's for fixing car exhausts and things, it's two part putty you mix together and can mold and mess with for about an hour before it starts to go off, when it does go off it's rock hard, sandable but really strong , I love it!

Also I started adding real world parts, the light is made up from bits of a torch and a spray can lid, the white nose vents are old rubbers from a skateboard ( thanks Sam! ) the rivets are upholster pins cut down and glued in

Step 6: Paint

Picture of Paint

I'm not sure what order other people build but this is the way I do, I got as much detail as possible on the main bit of the lid then I start the paint, on this one I primed it with whatever was around, then I used hammeright smooth silver, it's good stuff and gives a good worked surface to weather later

Step 7: Weathering

Picture of Weathering

Right paint is dry and time for one of my favorite bits, weathering, I use a black satin gloss and paint it sections, then use old rags to pat off or rub the paint, I get it how I want it and then add bits of browns and dark colours, till I'm happy, then I walk away, otherwise I'll do it to much!

Step 8: External Parts and Stuff

Picture of External Parts and Stuff

The main helmet is pretty much done, here I added bits and bobs to make it more like the game helmet, because I can't really afford to spend a fortune on my projects, I've been thrifty, the side bits that screw in are feet from a old unit, the arm that comes from the side is a metal ruler bent and shaped, the red eye piece is the top of a old spray can, the side pipe is a washing machine pipe, there's a small led torch on the arm which I've multiputted up to look old and fixed with a few found bolts, all then painted with the smooth silver then weathered to match the lid, then fitted, I've also started adding the LEDs to put in the main torch and red eye ( the LEDs are a ten string bunch of Christmas light with a battery pack all in one, all gathered up and glued it place)

Step 9: Nearly Done! Promise!

Picture of Nearly Done! Promise!

It's getting there, it always amazes me writing these up , it sounds so simple, but what you've just read is about. 6 weeks work, working only on a night after work and when the kids have gone to bed, anyways here we are, looking pretty cool right now, everything's tying in together nicely, pretty much just the main pipes and back bit to do

Step 10: Ten Steps Is Enough! Go Have a Cuppa!

Picture of Ten Steps Is Enough! Go Have a Cuppa!

The pipes where from a Hoover ( thanks Andy!) and cut to fit, the back of the pipes where there held was made by plumbing parts I had about, they fit together really well, I screwed the plumbing bit into the back of the helmet then fixed to pipe into them, added a few details with multiput and painting, with the multiput I had left I tidied up the inside where the pipes come in and other bits, also making the joins much stronger, anyways that's pretty much how I've made this one, I hope you like it, I'm really pleased how it's come together for no money really,

I will try to move on now, ( secretly I'm making a nord helmet mark 3! But don't tell anyone!) and I'll try to get out there and embrace the cold and get some woodwork done or start on a different project...................maybe!

Thank you so much for having a look , I hope you like the use of found parts and hand made parts, the thrifty way it's come together on a shoe string budget, I'm quite proud of this one , considering I wasn't going to make it to start with, and just see what I could learn ,

Thanks again and feel free to comment but please be gentle, I'm cold turkey with helmets now! ;)


KimberlyD79 (author)2017-04-19

So what is "multiput" is there another name for it? I can't find it. I know what bondo is. Is it some kind of epoxy. I was going to make a fallout helmet. I was going to to it without instructions etc. But i like the multiput thing to make some of the details but i Googled multiput and it doesnt seem to exsist.

matson23 (author)KimberlyD792017-04-20

I'm sorry that's my bad, it's actually called milliput, but my predictive changed it to multi and I didn't realise, sorry about that, it's handy stuff, mix it like playdoh and then it hardens after about 20 minutes

Psiborg (author)2017-03-28

Also, this is a similiar PDF, I don't know if you can add it?

Psiborg (author)2017-03-28

Nice. One of the best Fallout helmets I have seen so far on here. I will be attempting to construct this.

Yorklogan (author)2016-06-29

If was wondering if you coat the entire object in bondo and sand it then resin it or is it the opposite I'm very confused on this

matson23 (author)Yorklogan2016-06-29

It's Fibreglass resin, you can get it at most hardware shops, once you've made the helmet from card, then you use the resin to harden it up, once that's dry, then you use the bondo, yes all of the outside of the helmet, thin layers, sanding as you go to make the shape correct, hope that helps

Yorklogan (author)2016-06-29

And I was wondering what type of resin do you use and how to use it as this is my very first time doing any of this

Generationmatthew62 (author)2016-06-06

one of my friends said he wanted to build a full suit of power armor but this is where i come in,i have to build the first model and if its OK with you can i put your instructables name on it and if you let me i will send u a Juggernog fridge with nuka cola of your choice but i also have to make one for Halloween during the summer

FranciscoC111 (author)2016-05-11

where is the file? I want to build one

AndrewB17 (author)2016-05-01

can someone with a pro account please send me the pdf? would be much apreciated

matson23 (author)AndrewB172016-05-02

I've never seen it as a pdf, a pdo pepakura file is easier to get, I don't have it anymore, but if you search the Rpf.Com you might find a pdo or pdf file,

DiegoC85 (author)2016-04-12

Where is the pepakura prints?

qwertyasdfqwert (author)2016-02-23

I can't download the designer on my computer, could someone put a PDF of the unused to print

matson23 (author)qwertyasdfqwert2016-02-23

Not sure there's a pdf sorry, you'll have to search for it

Images not unused

BjarkeMNielsen (author)2015-11-03

Hey great build! I have a question; can I use something else than bondo, because I can't get bondo in Denmark?

BenO10 (author)BjarkeMNielsen2015-12-29

Just use another brand of automotive body filler.

GLaDOS_ (author)2015-10-23

I WIll BUild tHis

nelson17675 (author)2015-09-27

Where can I find the pepakura file that you used?

SovernSinner (author)2015-08-22

I cant find where to go for the paper of that helment

james.magro.18 (author)2015-06-27

I'm still trying to figure out the scaling on pepakura -.-"

Timmothy Green (author)2015-04-22

Would you be willing to sell a mask or not im not very crafty

matson23 (author)Timmothy Green2015-04-22

Sorry man it's not for sale, I still have the armor to make one day

Timmothy Green (author)2015-04-22

Would you be willing to sell a mask im not very crafty

ArtemisEntreri (author)2014-07-16

Being a big nerd and a megafan of the series... man that helmet is AWSOME i can't describe how cool it is :D

matson23 (author)ArtemisEntreri2014-07-16

Well thanks man! I've made a lot of lids and stuff, but this is still one of my favs, all we need now is fallout 4!!! :)

ArtemisEntreri (author)matson232015-01-14

we need actually even a serious mod for android to make a proper pipboy :P

Blacktron109 (author)2014-05-15

Wow, this is an AMAZING build for the helmet! I want it.

Vault Specimen (author)2014-05-13

I want one so bad. This is amazing.

gunnyboy (author)2014-03-18

This... This is amazing. Have you considered submitting it for the papercraft contest? Technically it is paper...

matson23 (author)gunnyboy2014-03-19

Thank you, I think I have a skyrim helmet in the paper contest, didn't think to put this in,

bcelik1 (author)2014-03-09

Amazing instructable! Got any tips on making pepakura crafts shaped well? When I do something, its almost always bent and misshapen

matson23 (author)bcelik12014-03-09

Hey man thanks for your nice comments,
The way I try to stop warping and stuff is
1. Use good thick ish card 200mgs is great for pep
2. Resin the thing inside first, and not to thick, and a few coats, with the skyrim helmet I taped the front to hold it in place while the resin goes off, scotch tape works fine, and easily removed or resinned in
3, then resin the outside
By this point it should be pretty sturdy and not warp when you bondo and stuff,
Aw yeah also I use super glue to make the pep file so that'll probably help to keep it's shape

Hope that helps you out dude! :)

bcelik1 (author)matson232014-03-10

I will definitely try doing resin outside :D I used a thick aluminium wire to give the overall shape and taped/hot glued it in. That worked kind of well but it made bulk with the resin on top of it.
By the way, do you know any other good glues to replace the hot glue? What kind of super glue are you using? Cryoacrylate dries fast but it is more expensive and tough to use.
Thanks :D

matson23 (author)bcelik12014-03-10

Like I said I use superglue, just standard stuff, but you only need a few dots and it drys real quick, just hold it for a few seconds and your good to go onto the next tab, no worries dude, always happy to help a fellow maker! :)

bcelik1 (author)matson232014-03-10

I use cardboard as the material. It is very thick and strong but it has its disadvantages. I should get thick bristol paper instead. I'm working on a gas mask now :)

Quick question, do you like Adam Savage?

matson23 (author)bcelik12014-03-10

Yeah it tried cardboard but I couldn't get away with it, not for pep stuff anyway,cardboard is good for beefing out the armor and stuff though, I'm doing the ncr ranger gas mask at the moment along with a few other thing that are on the go,
Bit of a random question but yes sure, he seems like a nice guy

bcelik1 (author)matson232014-03-10

You are? I am too! Got any tips from experience? :D I only made the gas mask part of it. I did two already from cardboard and made a good template a4 from the pepakura files that will be a better fit for cardboard.

I asked because mythbusters is one of the best shows for a maker like us :D Do you know about the short series of Stuck with Hackett

matson23 (author)bcelik12014-03-10

well thats where its at at the moment, main mask is done kinda of, bit more tidying up to do, also should be able to fit a proper filter in the side and use it for a sanding and resin mask, the helmet is a found one that im modify to fit, if it looks ok ill go with it, if not ill make the pep one,

As for tips mate, im not sure, just keep at it, it sounds like you know what your doing already! :)

Never heard of stuck with hackett, ill have a look for it later, if you look for theres some great links on there to stuff he does, untitled adam savage project, and one day builds and some cosplay stuff and more, its a great sight well worth a look!

bcelik1 (author)matson232014-03-10

Wow. nice work! You are good at this, dude.

Of course I know about tested ;) Have you seen the rocketeer one, that was amazing.

These are the test ones, the pepakura model was too large so I had to scale it down a bit and modify some pieces to make it resemble a rubber gas mask. The first one was much of a failure considering the bondo-like substance had small tensile strength and was cracking. I covered it with glue but it made it look like it was a kindergartener's paper mache project. I had to give in some metallic paint to finish the unintended make-shift apocalyptic effect. The next one will look better, I promise :D

matson23 (author)bcelik12014-03-11

You know if you get the pepakura designer program for your computer you could scale it down on there and measure your head and get a good fit that way, it would save you a load of work, they look good mate you've got the scale and design totally right, once you get the mask made, give it a coat of resin first, then I use car bondo, ( p38 flex filler stuff) I put on a thin coat and then sand, it has a bit of give in it so it should crack, also it's easy to sand so you can really pick out the detail like in the front filter and round the eyes, your pretty much there dude,you know what your doing and they look good, you just need to keep at it, take your time and have some pictures of the helmet to keep referring to, that's what I do anyways! :)

matson23 (author)matson232014-03-11

That should read, shouldn't crack!, predictive text on my phone try's to tell me what to write,
Also if you go onto my profile and have a look at the stormtrooper build, it goes into detail about the bondo and resin work, might be worth a look if you want to try it that way! :)

bcelik1 (author)matson232014-03-11

Have you done a cardboard rifle or a gun prop? I'm making a remington model 700 for a zombie walk we are going to have. Zombie is not really my thing as I prefer fallout style nuclear or biological apocalpypses. Yeah, I'm gonna check out the stormtrooper again. Thanks mate :D

matson23 (author)bcelik12014-03-11

No problem, I just did the aer9 lazer rifle from fallout 3 and new Vegas, that's the only gun prop I've done so far, that to is on my profile page dude, have a look, there's a few things you'd probably be into if your a prop/gamer like myself!

bcelik1 (author)matson232014-03-11

I have checked them out :D Awesome stuff, man. I was wondering on the more specific subject of cardboard weapons. Aer9 was wood and foam, no? How do you think I should progress with this gun? It has to be painted but Im afraid the paint wont stay because I applied some duct tape on it. Got any cool ideas?

matson23 (author)bcelik12014-03-11

That looks cool man, for the painting on duct tape and card, try get your hands on a cover all primer paint, in spray or paint on, a few coats of that first then do your paint job on top, that should help, then when your done get some satin clear varnish spray ( it's about £5 here, not sure where you are but it's in craft shops or home depo type places) once you give it a few coats of that you should have to worry about the paint coming off.

bcelik1 (author)matson232014-03-11

I couldn't find primer in the hardware stores I checked; I don't have the money anyways :/ But I will keep it in my mind, primer seems very useful. I just finished the paintwork. I covered the duct tape parts with paper and sprayed on top. Let's see how it works out. Do you have a facebook profile we could talk on?

matson23 (author)bcelik12014-03-11

Cool you'll have to post a picture or do an instructable for it when your finished!
I don't really do the whole social media thing but you can leave questions and stuff on people's profile pages on here( orange board I think it's called) I always to to get back to people when I can! :)

bcelik1 (author)matson232014-03-12

Here is the full zombie-hunter-medic-random-cigar-dude cosplay :D

matson23 (author)bcelik12014-03-12

Looks awesome dude! And looks like the painting on the gun worked out in the end then! :) good work!

About This Instructable




Bio: im a fixer,hacker,maker and shaker
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