How to make your own Fallout 3 helmet prop!

Step 7 Detailing

How to mix bondo body filler:

1) Get a FLAT clean surface made of plastic or metal (plywood is not acceptable). 

2) Scoop a 4" diameter dollop of filler onto the surface.

3) Squeeze out a 1-3" line of hardener. A 1" line is what is called mixing the putty "cold". This means you will have more time to work with it, but it takes considerably longer to dry. If you use too little hardener it will never dry and will always be sticky. If you use a full 3" line of hardener you will be mixing it "hot" This will give you quick drying times and a very hard finish. Unfortunately it will be more brittle than mixing it cold. 2" is the median and is what I would recommend.

Using a putty knife, fold the hardener vigorously into the putty so that it is mixed evenly. Don't take too long doing this or the filler will begin to harden while you are mixing. 

Now carefully apply a generous amount of putty to the area you are trying to fill or shape. 

When the putty is hard but can still be dented by your fingernail use a small Sureform file to roughly shape the putty. You can also use some 80 grit sandpaper for this. 

Now allow the putty to cure completely. When cured it will be hard like plastic, and will be giving off no heat. 

Now do your final forming with some 360 grit sandpaper, elbow grease and finish it up with 1200 grit for painting.