Blaxmyth
Sr Member
I’m a great fan of the Discworld novels, particularly the Guards series. Recently I adapted a morion helmet pep file into something like I imagine Vimes and his colleagues wore.
It’s a very simple file to build and shouldn’t need resizing at all. It’s designed to come down fairly low over the ears and there is still room for a liner or foam padding.
Files here: Ankh-Morpork City Watch Helmet 3 - Download - 4shared
The file is on A4, but there is plenty of space around each piece and it should transfer easily to Letter format.
I stiffened the outside of the pep with two coats of resin. I have tried with one coat, but the second coat really tightens the pep and stops it from distorting when the rondo starts to set.
After the resin has cured I waxed the inside of the pep with Carnuba wax. I used to use the cheap car polish paste, but have found that the more expensive Carnuba mould release is well worth the extra expense. Just rub it in well with a soft cloth.
I used a full paper cup of rondo in each helmet, rotating it to get an even coverage, using a brush to spread it around up onto the rim. It was somewhat tedious, but stopped the rondo from pooling in the lowest part. I used two thicknesses of fibreglass cloth, fairly light weight and well wetted in with resin.
The bonus of using the wax was that the pep came away almost in one piece. It was almost good enough to tape together and use a second time. The helmets just need to be sanded and built up with some bondo, then painted, weathered and fake rivets added.
Hope to have some pics of the completed helmets up soon. Cheers, Phil
It’s a very simple file to build and shouldn’t need resizing at all. It’s designed to come down fairly low over the ears and there is still room for a liner or foam padding.
Files here: Ankh-Morpork City Watch Helmet 3 - Download - 4shared
The file is on A4, but there is plenty of space around each piece and it should transfer easily to Letter format.
I stiffened the outside of the pep with two coats of resin. I have tried with one coat, but the second coat really tightens the pep and stops it from distorting when the rondo starts to set.
After the resin has cured I waxed the inside of the pep with Carnuba wax. I used to use the cheap car polish paste, but have found that the more expensive Carnuba mould release is well worth the extra expense. Just rub it in well with a soft cloth.
I used a full paper cup of rondo in each helmet, rotating it to get an even coverage, using a brush to spread it around up onto the rim. It was somewhat tedious, but stopped the rondo from pooling in the lowest part. I used two thicknesses of fibreglass cloth, fairly light weight and well wetted in with resin.
The bonus of using the wax was that the pep came away almost in one piece. It was almost good enough to tape together and use a second time. The helmets just need to be sanded and built up with some bondo, then painted, weathered and fake rivets added.
Hope to have some pics of the completed helmets up soon. Cheers, Phil
