Don't even dare read this Instructable unless you have read Volpin's Daft Punk helmet
tutorial first. If you're satisfied with sub-par, stay on this page. If you want perfection GO READ HIS RIGHT NOW.
This instructable shows how YOU can make a Thomas Bangalter Daft Punk helmet. I watched a lot of youtube videos about making helmets like this, and this site was a big help: http://www.thedaftclub.com/
Here is a video of it in action:
Step 1: Materials
Materials:A helmet of some sort,
generally a batting, skateboard, or some other rounded helmetCardstocka PrinterMasking TapeElmer's glue2 Aluminum CansFiberglass Resin
I used Bondo Fiberglass resin jellyBondoA sanding implement
Like sandpaper, or a powersander, or something like thatSilver Spray Paintan extra visor for a safety mask
for the visorSpray on window tint
to make the visor blackThe Paper Files
download them here: http://www.mediafire.com/?sharekey=5f31918b5d7318337069484bded33bcdee851c20c3cd01fa
Step 2: Assemble the Paper Part
if you haven't already downloaded the pdf's that contain these files, download them here : http://www.mediafire.com/?sharekey=5f31918b5d7318337069484bded33bcdee851c20c3cd01fa
You will use these so that you can make a perfect front part of the helmet. Print them on your cardstock, cut them out, and glue and tape them together using Elmer's glue, and masking tape.
I got the paper files from this guy: http://www.youtube.com/user/CRTSHCTR
He makes awesome helmets!
After you have assembled the paper model, cover up any holes on the helmet using masking tape, and cardstock, and then attach the paper model to the front of the helmet, using masking tape, and adjust it until you feel satisfied with its position. You can attach the ears if you want, but I was going to attach the ears after I put enough fiberglass resin on it.
Step 3: Cover in Fiberglass Resin
I covered the whole thing, section by section with small amounts of the fiberglass resin jelly. You mix the Resin with the hardener, and then apply it to your helmet. The label says it takes 30 minutes to dry, but I wouldn't really listen to that, because it takes a lot longer than that. If you have previous experience using Bondo, this stuff takes more than twice the time it does to start to set, so you have more time to smooth it out. Try to get it as smooth as possible before it dries, because there is a lot of sanding to do no matter what you do.
Step 4: Adding the Ears
You now need to put together the ears, if you have not already done so. You need to cut the bottoms off of two aluminum soda cans, and the attach around them the Ears that the paper model pdf's contain. You may then attach them to the helmet with masking tape, and make sure they are nicely aligned, and symmetrical because once you put the fiberglass resin on them, it is hard to change.
You may now commence to vigorously sand the helmet, and await further instructions from me.
To be continued...
Step 5: Sanding..
The thing that you will be doing most in this instructable is going to be sanding.. so get used to it!
Step 6: Adding the Bondo
Now apply the Bondo, mixing it together using the instructions on the can. Sand inbetween applications of Bondo, to make it easier to apply the next coat.
Step 7: More Sanding
Sand frequently, and add more Bondo to spots that need to be filled in. I also sprayed on a light coat of the Chrome paint to help me see where I needed to focus the most attention on. Use progressively smaller gritted sandpaper, until you feel satisfied with the job.
Step 8: Spray on the Paint
Add some more paint, and let it dry, and continue adding more until you are satisfied.. I used the whole can on my helmet.
Step 9: Cut out the Visor
Cut the visor out of your safety mask, by tracing the design on, and then cutting out with a jigsaw or a dremel tool. Try to cut it out as cleanly as possible, but if your edges are a little jagged it should be fine since it will be covered up by the helmet. Then spray on the window tinting.
Step 10: Assemble It
Put the visor in the helmet, it should fit if you did everything right, and just slide it in, and adjust it until it looks right. It is finally done!
Post your finished pics if you want, I would love to see how other peoples turned out!