Firstly, I would just like to thank everybody. Their support, ideas, philosophy to help others and great attitudes have helped me, and I'm sure other beginners like me start their first projects.
So I'll begin. I crafted the primary one out of foam. I just bought a few EVA FOAM mats from ebay. They're roughly 10mm to 12mm thickness. I think closer to the latter, which made them a little too thick in my opinion. Regardless. I purchased a Dewalt heat gun, a glue gun and some few other bits.
My biggest problem in my horrible first build was cutting. And rushing. You need to take your time with these things. I thought I'd buy a hot knife to make the cutting cleaner, and easier.
The thing broke by the end of my helmet build, was difficult to use, and because heat makes metal expand, the blade kept falling out regardless of how tight I made it. Sometimes onto work I had just finished (ruining it in the process. I bought this one: Weller Woodburning and Hobbyists Kit: Amazon.co.uk: DIY & Tools - So steer clear of that!
This was the beginning:
Then finally, the rest completed:
- There were alot of imperfections. I didn't like them. I thought the best thing to do would be to buy Bondo (Or at least the UK alternative, P38) and then sand off the imperfections.
This was another mistake. Firstly because I didn't know how to use bondo correctly. I smeared it too thick (and i mixed up so much, it dried before I could use it all. Idiot!) - regardless, I did what i did. I used a mouse sander and sanded it down.
This is what's left. To get some detail back, some edges needed to be sanded right back to the foam.
The ears are also a problem. I can't seem to sand them right, and the shape is becoming all malformed.
Also, I didn't anticipate that the P38 would crack and be so choppy in places as it is. Ultimately I think I've ruined this by adding P38.
Ultimately, I'm a little disappointed. I know everyone says don't get started on the helmet first. But finishing the helmet would also give you enough inspiration to do the rest.
I'm not thinking of giving up. But I work 3 jobs and am a full time student at the same time, so having the time to do this is getting iffy. Plus the space, I just live in an apartment, no garden. I can't see this going anywhere for a while, and I'm not yet sure if I would want to start from scratch again when I have more time. Perhaps with tidier, thinner foam.
In any case, I thought I'd share some of the issues so others might not make the same mistake.
Also, I'd like to extend my deepest gratitude to XRobot's James, who's time and time again, put up with my annoying and repetitive questioning in order to help me, Stealth, and all of the other big names who've shared and helped.
Anyway guys Nice to meet you! Any questions please ask!