Step 4: Filling in the dome

Now cut some long triangular cardboard wedges. Start by bending these as close to the curve of the dome frame as you can. Start by gluing the wedges to the frame first with the hot glue gun, then working your way gradually to the middle of each frame section. There will be a lot of trimming and adjusting involved so take your time. Getting the curve of the dome right will make finishing the helmet much easier. After the dome is filled in smear all the seams on the outside of the helmet with white glue. You can see that I've also cut out the opening for the visor at this time. Now drop that bucket on your head and make sure it fits the way you want it to.
so finished the helmet(had alot of fun building it).im trying to build this helmet.do u think i should use the newpapaer board or should i use a boba fett helmet as a base and paper mache from there on.
<p>I would say paper mesche and/or pepakura.</p>
I'd make it from scratch- it's too different. You might do a search and see if someone has already made a template for it.
Here is my helmet i used the cardboard at the bottom but used plaster for the top
&nbsp;Its awesome
Awesome!<br />
Here's a preview for the next cardboard project- Rocketeer! I've always wanted to do this one. The helmet patterns are almost finished and then comes the jetpack..... stay tuned for Halloween. :)
hows the rocketeer helmet coming?
It's getting there but it's going to be a while before the project is finished.
cool, i wish i could do something as cool and inspirational as this
Gasp! I love that movie, and no one's ever heard of it! Stop encouraging my fetish for heroes with jet packs. Great job BTW. <br/>For those of you who want to make helmets on the cheap, art stores sometimes sell silver reflective paper that looks a lot like metal until creased. For some reason, my school had reams of it, so I used it to make a murmyllow sp* gladiator helmet (one with a fish crest). It stayed in my car for months and I wore it occasionally to scare other drivers.<br/>
I see the dome of the helmet looks to be tricky. I measured around the boba fett helmet and then blew up a balloon to that size. then i paper machete the balloon. it worked great and was so easy compared to all those triangles.
bloody good idea
On the topic of blender, do you have to model the helm from scratch, or can you upload a pic or something?
I had to model it from scratch based on reference photos.
But you can upload a pic to paste into the backround of blender so you can kind of trace over it in 3d.
You sure can- the trick is to get them scaled the same.
Could you send me the .blend file of your rocketeer helm, I am interested in modifieing it to suit the helm I am designing. (minerug@hotmail.com)
Sorry, but I'm not posting it until it's finished- there's still a lot of work to do! There are a ton of online Blender tutorials- just click the help button in Blender.
ok, np
Also look up blender noob to pro wikibook. Its THE BEST learning guide!
ok, thanks
How long doe it take to make a pattern like the rocketeer?
I could probably do the 3d design in a couple of hours now that I sort of know what I'm doing. A really complicated design could take several days.
Holy crap its blender!!! I lOve blender! but how do you make the template? (into a flat page that is?) How exactly could you do that in blender without having to manipulate all the edges yourself?
Blender is great! This is actually the first 3d object I've ever done. Make your model in Blender and then import it into Pepakura Designer to make your template. Pepakura is just awesome.
One question though--- how exactly do you get the .blend file into a usable extension??
You have to export it as a 3d file such as .obj or .3ds
Dude thanks! Pepakura rocks!
Here is my spartan helmet
hello i love this helmet, you are great. can you please tell me how you did it? what are the measurements that you took? thanks allot.
For those whom this may concern, I've revised that Leonidas Spartan template to make it look more like it did on the movie.
Here are some pics of my helmet. It's made from a child's batting helmet (I cut out most of the padding for it to fit), I cut off the visor and about 1/4 of the back of the helmet (the back is actually the front. I cut the faceplate out of two paper notebooks (the cardboard in the back). I used gorrilla glue to glue it on and duct tape to hold it in place while it was drying. for the crest I cut a couple pieces of some thin board, glued it on, put play-do inside of it, then I used bristles from an old broom to stick in the play-do. Then I sprayed it down with metallic gold spray paint. I used black paint for the crest
Great job!
Awesome! What did you cut the batting helmet with? Also, what are the measurements for the revised face plate? I'm making a similar one.
The faceplate measurements are as is, except I went ahead and stretched out the top as far as I could. I cut the helmet with a jig saw.
uhm... i'm a little hard up to do it since i'm still a beginner<br><br>so i request for a video in doing it :)<br>
Next time I make something like this I'll definitely try to make a video!
<p>Good article....</p>
<p>I have a quick question. What did you use to make the Visor for the helm? How did you make it and where did you get the materials?</p>
I cut it out from a clear plastic face shield from the hardware store (Home Depot I think) and then tinted it using auto window tint film from Auto Zone.
<p>Thank you so much for this instructable! This was my first time making anything like this. It was quite the experience :]</p>
I have a pretty big head and am worried about the template being big enough. Is there a way to measure/scale the template?
I can tell you the movie sized helmet is pretty darn big- it's very rare that someone says it's too small for them. I have a large head and it fit me no problem. You can scale the templates by changing the print size but I don't know exactly how to scale it according to your head size.
Thank you so much for sharing your knowledge. This helped me so much while making my Sabine Wren bucket. <br><br>I do have some questions about the Polycyrlic process. <br>How many layers did you add before painting?<br>Did you sand them between coats?<br>Is there another sealer you would recommend that works better? I read somewhere that Casting Resin can be used to coat the outside. Not sure if it will hold well to Spackle paste? What do you think?<br>Oh and...<br>What paints stick well to the Polycyrlic Water-based sealer?<br> Sorry for all the questions. <br>Thanks again!!
Thanks- glad you like it! <br><br>I only applied one coating of Polycrylic sealer and that seemed to work just fine. As long as it seals the cardboard I see no reason to apply more coats. I haven't seen casting resin as a coating but I have seen people use polyester resin (the smelly kind used for fiberglass work) applied to cardboard and that works just fine and will make the helmet a bit stronger. Epoxy resin would also work.<br><br>Coating the helmet with resin would require you to use a filler like Bondo instead of spackling paste as I don't think spackling paste would bond to resin. In this case you would apply the Bondo filler after you have applied resin and it has cured. <br><br>I've used both enamel and acrylic paints with Polycrylic sealer and both work just fine.<br><br>If you have any other questions just let me know!<br> <br><br>

About This Instructable


1,931 favorites


Bio: I'm a former bicycle industry designer turned professional jeweler. I like working with my hands and am happiest when I'm in the shop ... More »
More by Honus: Science Fair Air Rockets DIY functional Sonic Screwdriver Rose cut natural raw Diamond ring
Add instructable to: