Step 1: Equipment
EberhardFaber light weight air drying clay
Plaskti-kote super enamel 686 gold
Ford Jupiter red metalic spray paint
wet and dry paper
A pair of old sunglasses
4 bright white LEDs (sold in car shops)
Step 2: Getting a Base Shape
If your going to make a cast of your head i would suggest asking a friend or two to help. fist off your going to need plaster bandages cut up into 2 inch sqaures. Have your friend cover your entire face with vaseline and either use clingfilm over your hair or a shower cap.
now get your friend to cover the whole of your head with about 3 to 4 layers of plaster bandages, leaving a gap over the top of your head from ear to ear so that you can get back out of it,
Once dry which takes about 20mins remove and then place both pieces together and join with more plaster bandages.
Once you have your basic head shape its time to start making a base for the helmet. i used plastercine to get a basic shape, extending the chin slightly and the forehead. all done by eye, i never had a template or measured anything, but you could try drawing out a template to help guide you.
Then i covered the whole thing with light weight air drying clay, and then waited for it to dry out before starting to shape it. I used light weight air drying clay in the past and found it very easy to mold and sand after it is dry, you can get a really smooth finish on it using wet and dry paper. but use the paper dry cause it shapes it easier.
Step 3: Cutting Out and Taking Shape
I then took the helmet off the model head and realised that i had done the eyes the wrong shape so cut them a little more and shaped it again. the eyes were probably the worse part to try and get right and symetrical but in the end i think they look ok.
you could try using a template for the eyes draw them out on a piece of paper, then cut them out, put them on the clay where you want the eyes to be and cut around them with a craft knife. this way you get them lookin symetrical.
Step 4: Building It Up and Checking It Fits!
Step 5: Reshaping
So i decided to put the helmet back onto the model head so it would keep its size, then i added some more clay to the top and the chin to try and get the shape right.
At this point its all about shaping and creating it the way you want it, so look at my example pictures and the way i added the clay. As the added parts dry out you can cut and sand to the desired shape and look.
Step 6: Detailing
to make the mouth i simply cut a 1mm gap using a craft knife, then removed the excess clay. To cut the holes in the cheeks i used a ruler and cut a line from the mouth to 1cm away from the curve at the top of the cheek bone. The curved part was all done by eye but you could use templates to get them equal on both sides.
to get all the details into the mask i used the craft knife and cut the lines into it but not too deep and wiggled the knife to make the gaps a little wider.
To create the screw looking parts i simply used the end of a biro pen and as long as the helmet hasn't dried solid you should be able to push the end into it and leave a perminant dent that looks just like a screw.
Step 7: Spraying and Finishing?
For the gold part i used gold enamel spray from halfords and for the red i used Jupiter red car spray paint.
first i sprayed the gold (about 5 layers) about ten mins in between layers once done leave to dry for about an hour or 2.
Mask off the gold area with masking tape and then spray about 5 layers of red, also this takes a little longer between coats about half hour so give yourself a day to do this! then leave for 24 hours.
once the red is lookin good and thick and shiny then remove the masking tape.
then spray coats of laquer all over both colours untill the gold and red are both looking shiny. leave to dry and then its ready to wear.
Step 8: Suit Preview
Step 9: Lighting Up the Eyes
then add two LED's either side of the eye, i used super glue to put these in too but you could also use a glue gun on these aswell. next add a switch to the cables and hook up the 12v battery then you should have glowing eyes!
hope you enjoying this instructable!