Riding my motorcycle on my weekend commute to and from work means I have to deal with a lot of air pollution. I usually wear a face mask to ward off the smoke and dust. In this instructable I made a cover for my face mask to make it look like it is integrated with my helmet.
So here goes.
Step 1: Get Parts, Design & Cut (just Do It)
1. EVA foam 2mm (one 12" x 12" sheet)
2. Mechanical pencil
3. Pair of scissors
4. Instant glue
5. X-acto knife
6. Acrylic Emulsion
7. White Spray paint
8. Small screws or anything to accessorize (optional)
Googling around for images, I found a futuristic robot style helmet. That's the gorgeous black thing above. The pattern seems easy enough to make so I drew and traced the cut outs on eva foam. Mechanical pencil marks the foam very well so I recommend using one. The pattern made was freehand so I just drew one side of the cheeks to the jaw. I just flipped and trace to create the other side.
Cut it up either using an X-acto knife or scissors.
Step 2: Assemble-fit-adjust-fit-assemble
This is the fun part, I assembled the foams together then fitted it to my face. I saw that it did not fit the way I wanted it to, so I trimmed and made some temporary holders to see how it should fit. The pictures show the changes I made from the initial design to the final form.
Step 3: Coat-Coat-Coat & Coat
I brushed on 4 coats of acrylic emulsion to smooth out the foam and make it less porous. Paint also looks smoother with more coats. 4-5 is a good start.
Step 4: Bring on the White Paint
Spray painted the thing white since my helmet is white. Coated this 3 times.
Step 5: Accessorize
I put some small screws just for accent, then glued on my old face mask.
Step 6: Wear It
This build took me a day to finish that includes trips to the local hardware to get paint and emulsion. mush of the time was spent on googling :D