Halo Hayabusa Helmet

before you start your helmet you must go downlaod a program called pepakura .. 
this program is completely free to download so you don't have to worry about spending money on it.

link:  http://www.tamasoft.co.jp/pepakura-en/

there are two different forms of the program pepakura...
pepakura designer and pepakura viewer. The difference is that pepakura viewer is used to view files that you've downloaded from other websites, and designer lets you design you're own 3d models. You will only need pepakura viewer for this project.

Step 1: Materials

You will need:

pepakura viewer 
Bondo 
fiberglass resin
facemask
cardstock paper
x-acto knife
craft glue
latex gloves
brush
spray paint(colors of your choice)
masking tape
old magazine or cutting board
sandpaper

Step 2: Printing the piece

First download the file containing the model for the helmet at....

http://www.4shared.com/file/55971021/23801b1f/Agbates_-_Hayabusa_Helmet.html

Once downloaded open the file in pepakura viewer. when opened there will be 2 windows showing the 3d model and the unfolded pieces of the model. now you have to print the pieces of the model by pressing print under  "file" at the top of the window.

Step 3: Cutting out the pieces

once printed out you must begin to cut out all the pieces.
*be warned there is a lot of cutting to be done*
use an old magazine or cutting board while cutting to prevent damage to anything you are cutting you're project on. you may want to use a bin or small container to keep your pieces in 

Step 4: Gluing the pieces together

to figure out where the pieces go you must match the numbers on a piece to another piece with the same number. you can also use pepakura viewer and move the mouse over a side on a piece and it will show you the piece that must be attached to that side. This part is very difficult and will require a lot of time to complete.  

Step 5: Fiber-glass resin

for this step you'll need to mix the fiber-glass resin with the small container of hardener, that comes along with the resin, as it says on the back of the container. Make sure you add the correct amount of hardener to the mixture, if you add too much the mixture will harden too quickly, and if you add to little it will take too long to harden. if the resin starts to clump up it means that you added too much hardener and you must make a new batch. 
using a brush and a small container to hold the resin, begin applying the resin to the helmet, make sure to only apply a thin layer of resin to the helmet. the helmet should have a glossy yellowish color to it after applying the resin. 
*Important* if you do not have the bondo only apply the resin to the inside of your helmet. Also wear a pair of gloves and a breathing mask during this step because health problems may occur otherwise.   

Step 6: Apply Bondo

Like the resin, mix the Bondo with the hardener that comes with it as it says on the back of the container. For this step, apply the bondo to the helmet. Try to apply a thin layer to the helmet as it will become very hard when dry. the mixter should be a dark brown 
** try to make it as smooth as you can because it will become difficult to sand down, also try not to aplply it to small spases as it will be difficult to sand down. i myself only applied it to the softer parts of the helmet because it was  becoming difficult to mold onto the helmet
*Important* make sure you wear a pair of gloves and a breathing mask during this step because health problems may occur otherwise. 

Step 7: Sanding

this step is pretty simple all you have to do is sand down the bondo until it is smooth... 
i used a sanding block for the larger parts as it made it easier to remove the bondo.

Step 8: Painting

ok your almost done :)... now you must apply an even coat of primer to your entire helmet once that dries spray the majority of the area(s) the color that you want it  (pics 1-4) after that dries apply a second coat to the same area(s) after you finish painting that color you must cover it with masking tape so that none of the other color hits it 
after your done painting spray the rest of the helmet the other color that you have chosen (pics 5-7) and then apply a second coat to that color.

Step 9:

once all the paint has dried you are free to remove the masking tape and you halo hayabusa helmet will be done 

Comments

[binaryCrusader]

Neat project, I was going to use this as "Vision Protection" for robotics tournaments just for fun. My only questions are: Will the fiberglass resin make it hard enough but not brittle and can you use a regular printer for the card-stock pieces.

[ijoyce]

Please please pleaase please could you do me the great favor of making a tutorial with all of the piece matching instructions? I have a mac and don't have pepakura viewer, only the .pdf file for the pieces... I have no idea which piece goes where and am really confused D:

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