I imagined something like the original Dredd helmet out of the comics mixed with the helmet from the movie. I took an open-face motorcycle helmet and cut out an inch down the middle to get the right size. I used the piece I cut out along with nuts, bolts, and apoxy to fill in that ginormous crack. The brow of the visor was made from the back of a bicycle helmet. A piece of motorcycle visor was cut into the right shape and plastic from a soap tub made the neck part. I used multi-purpose filler over the whole helmet to get the shape I wanted then sandpaper smoothed things out. I used a paint brush for the primer, and spray paint in red, black, and gold. The battle scars were made from paint I sprayed on the cardboard and then I wiped it on to make it look like bullet and wear marks. All this and two months of hard ass work.
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