Instructables
Always wanted to make a helmet from Halo, Daft Punk, Gears of Wars, or any other iconic character that you like a lot? This instructable is for you! (And it works for armor too!) 

Obs: This is my first instructable, and if there is any grammar mistake, sorry, english isn't my first language! and the .PDO for Guy's Helmet is in step 2.
Obs²: Gloves tutorial are now on page 10!


 
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Step 2: Paper model!

Print out your paper template in Pepakura Viewer, cut out and start gluing everything in place! (How to do this is theme for another instructable)

Here's a tip for gluing the parts togheter: http://www.instructables.com/id/Pepakura-armor-making-quick-tip/

Update: I've uploaded the pepakura files for people that wants to make the same helmet!
http://www.4shared.com/file/GjlA4-nw/Guy_Manuel_Helmet.html?

Step 3: Fiberglass!

Apply your fiberglass mat or cloth and resin over your paper helmet or armor, let it dry and it will be hard as a rock!
(TIP: Fiberglass the inside, not the outside as I did)

Step 4: Bondo!

Picture of Bondo!
Apply bondo to the places you need to get smooth! (Normally round or curved places, straight parts don't need to be "bondo'ed")

Step 5: Sanding! (And lots of it)

Take your various grit sandpaper, and start sanding from 150 grit, until 600 or even 700 grit! Get everything nice and smooth or you may regret it in the future!

Step 6: Painting!

Take your spray paint and put a layer of primer on this helmet! Sand off any imprefection and primer again if needed! Then, your final color and a layer of clear laquer!

Step 7: Visor!

Picture of Visor!
Next you need to add a vior, and you can buy plastic, plexiglass, a motorcycle helmet visor, but in my case I needed to vaccumform a visor! And attach it with superglue or hot melt glue!
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mechagical11 days ago

When you said you made a mistake by fiberglassing the outside instead of the inside, how was it actually?
Also wouldn't fiberglassing the inside make the helmet smaller to wear? Because i think it would kinda "fill" the space.

could you make it without fiberglass because i can't use that

Late reply is late, but look into something called epoxy resin. If your in the states, I would recommand using TotalBoat 5:1

DoctorWoo1 month ago

Since this was the post that got me into prop building, I figure it's only fair I share something I just found out!


Polyurethane resin (as used in here) is really smelly and can cause issue. For some people, this isn't an issue, as yard space and weather is on their side. It's also cheap, easy to find, and does a good job.

However, if you don't have a yard, or don't have good weather, you can swap out from polyurethane resin to a two part epoxy, more commonly used for boat building. Although it is a tad more pricey, it can be used inside! though, you will want to get air flow as the epoxy resin smell (though not as dangerous as polyurethane) can case issues in small spaces. It's also very picky on mix ratios. Most good epoxy systems (TotalBoat is what i use) comes with a pump system that you can use that means you take one pump of part A and part B. This sounds bad at first, but since you have a set ratio of the two, this means you can mix up only what you need and have little to no waste. And! Added bonus! You can make body filler by mixing the epoxy resin with an equal part talcum powder (easily found in baby powder!) to thickin it as needed. So what you pay for polyurethane resin and body filler you more or less equal out to in the end with epoxy resin and baby powder.

The best part of all though: this awesome ible' can still be applied to either polyurethane or epoxy resin!

OxyPinecho11 months ago
After hours of cutting and pasting, i have come to the realization that the template that you provided is too small for my head. Will it get larger in future steps, or do you have any other templates?
OxyPinecho11 months ago
Did you add the fiberglass to the body and visor separately or together then cut the visor out?
degomag1 year ago
Boa japa!
FabiojapaXD (author)  degomag1 year ago
Valeu!
o__o2 years ago
What did you use to stick the peices onto the gloves? Nice work btw. :)
FabiojapaXD (author)  o__o2 years ago
Thank you! I used simply hot glue gun! It works wonders actually!
Cool thanks! I'm making a daft punk costume. This helped alot. :D
FabiojapaXD (author)  o__o2 years ago
And that is very nice to hear! You may ask anything you want, someone to help is very useful! (
ikendall2 years ago
vai Brasileiros/as no Instructables!!!!!!!!
FabiojapaXD (author)  ikendall2 years ago
Woooooo! Brasileiros dominando a internet! \o/
lol, parabens cara, já tinha ficado fod@o, mas agora....xD!
FabiojapaXD (author)  thealerosenbaum2 years ago
lol valeu xD
Shonswer2 years ago
It's like Daft Punk style! Nice tutorial bro!
FabiojapaXD (author)  Shonswer2 years ago
Thank you very much!
PeckLauros2 years ago
Da para colocar o esquemático ou pelomenos um esboço do circuito eletrônico?
FabiojapaXD (author)  PeckLauros2 years ago
Pronto! Coloquei o circuito na pagina 8!
Valeu! Ficou Fda!
When you put the fiber glass mat/cloth on how did you keep the paper structure from collapsing on itself?
FabiojapaXD (author)  ThunderDrums2 years ago
Here's a tip: First, I glued the fiberglass cloth in the helmet, with normal, white glue, and then I brushed the resin over it, so it wouldn't collapse or distort so much! But, try to fiberglass THE INSIDE, and put some wooden pieces on the sides, so it won't distort! (If some distortion occurs, take a heat gun and gently heat the warped part and try to bend it in place)
DoctorWoo2 years ago
Don;t suppose you have the file for Guy's DaftPunk helmet, do you...?
FabiojapaXD (author)  DoctorWoo2 years ago
No, I lost my file and the link I used to download was on Megaupload. Sorry man. If I find one similar I'll post the link!
Drat. Been looking for those for some time. But this is a great find none the less! Really helpful for any sort of prop making!

However, I got one more question...you said you vacuumed formed the visor..do you have a vacuum form machine, or do you have some sort of a nifty trick of the trade?
FabiojapaXD (author)  DoctorWoo2 years ago
I did try to make a Vaccumformer, but it didn't worked as suposed to. (It was simply a box with a hole for a vaccum cleaner hose and a lot of small holes on the top)

One visor I made with the vaccumformer looked great, but it was too smal do install on the helmet, so I made one by simply heating the PETG plastic in the oven and putting it over the mold, simple like that!

PS: I've uploaded a file that I found, it's not mine, I'm only uploading it!
http://www.4shared.com/dir/wvwjyYAJ/_online.html
57.JPG58.JPG
Oh! Thats clever! I used one a few times when doing some 3D modeling in school. Very nice machines to have, and from the looks of it, easy concept to clone!

I'm actually planning to make a helmet here soon, and the visors *always* threw me off. I've seen and heard of some people actually getting a thin plexglass and using a heatgun to form the visor...have you ever tried that...?
FabiojapaXD (author)  DoctorWoo2 years ago
Yes, because the visor that IS mounted on the helmet was made somehow like you said, but instead of a heat gun, I used a oven xD But eventually, I'll buy a heat gun, very useful for me!
And sadly yes, the visor is the worst part of the build, but when you start to get it right, you will feel awesome! So, if you do make a helmet, send me a picture!
And I didn't used plexiglass, but PETG, a plastic that was 0.75mm thick!
Ah! PETG, that's what I was thinking of! I've vaguely remember another plastic people have used for visors, but my memory failed me XD
But I will certainly upload some pics when the project gets underway! Hopefully I can find a good model here soon!
FabiojapaXD (author)  DoctorWoo2 years ago
For the guy manuel helmet? Didn't you see? I said I uploaded it!
http://www.4shared.com/file/GjlA4-nw/Guy_Manuel_Helmet.html?
:O I didn't! Oh, man...your my new best friend! Thank you TONS for that!
FabiojapaXD (author)  DoctorWoo2 years ago
Your welcome man! I found the file hidden in some part in my computer and thought that would be useful for a lot of people! And don't forget, I want to see the pictures! xD
I defintaly will!!
But, before I do..I got one finally question: how'd you tint the visor? Did you buy the PETG pre-tinted, and if so, from where?
FabiojapaXD (author)  DoctorWoo2 years ago
My visor, I bought the normal PETG, and used a paint, but I can't tell you the name because I'm from Brazil, so you wouldn't be able to find, but it was a paint used to tint tailights of cars, the American one I think is VHT Nite Shades, it should work just like mine!
PS: The image below shows the visibility of the visor :D
Good luck with your build, any question just ask me!
92.JPG
Oh! Alright, perfect! Thanks for that!
And I think I lied...I need one last bit of info for this...don't supposed you have the wiring schematic for the lights, do you...?
FabiojapaXD (author)  DoctorWoo2 years ago
Actually, I do xD The Controller was this one: http://www.eleccircuit.com/wp-content/uploads/2007/05/led-chaser-by-ic-4017-ic-555.jpg (Connected to 8 AA batteries, resulting in 12v) and the led boards, I simply used 4 5mm ultra bright leds in parallel, with one 470 ohms resistor for each one!
The design for the controller board, sadly, I can't upload for you because it isn't mine, but for the leds I'm attaching a print screen for helping you!
help.png
PeckLauros2 years ago
Ficou bom p/ caramba!
FabiojapaXD (author)  PeckLauros2 years ago
Opa, um Brasileiro no Instructables! Valeu cara, é sempre bom ouvir coisas assim!
toezar002 years ago
Nice Helmet.
Nice Gloves.
Nice Job.
Looks Awesome.
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