My first thread- Iron Patriot cardboard pep helmet

[HarasiElite]

Forgive me if I make any errors on here but here goes my first thread

well I'm going to make an Iron Patriot helmet from cardboard, fibre glass and bondo. I have made a helmet before with these materials and frankly the finished product was very rough:eek So this time I am going to use what I have learnt from before and this time produce a beautiful Patriot helmet!

Last night I got to cutting and sticking the cardboard sections together (I had already cut out the paper templates from before) and I think it's looking pretty good so far; if you think anything needs adjusting or looks odd, please let me know, I want this helmet to be great! (The other Patriot helmet that I made is simply cardboard and acrylic paint)


pics so far:

 

[HarasiElite]

today I got a bit done, did the inside of the eyes and mouth with cardboard to help keep things nice and tidy for fibre glass which I will hopefully do tomorrow.

 

[HarasiElite]

Got the fibre glassing done, I'm only doing one layer otherwise it will become too heavy and probably also too tight for my big head!
hopefully i'll get the bondo on soon but school starts again on monday so I will have to find time for this...

pics:






Oh and does anyone know if I am supposed to harden the outside of the helmet at this stage? I have ran out of resin, so could i use PVA glue or something?

 

[GavinSchulz2000]

Subscribed! This is really cool i resined my deathstroke helmet inside and out before I fiber glassed but I bet Pva glue will work just fine


- Gavin

 

[Atymisk]

Its recommended that you coat the outside too, so the outer layer doesn't cause any problems with the body filler stage by keeping the surface sturdy

 

[HarasiElite]

Thanks for the input guys! I think I'm gonna go ahead and put a couple layers on the outside of the helmet because it is still soft cardboard after all:rolleyes

I haven't got to the bondo stage because of being busy and i don't think i will get it done too soon, but hopefully by the end of the month i will have applied a layer!

 

[Murdoch]

Looking good so far, keep it up man...GM

 

[HarasiElite]

So I finally bought a Dremel and it does not dissapoint! I used it to remove the excess fibre glass from the helmet.

pics:



I also applied one layer of PVA glue (slightly watered down) and now the outside of the helmet is stronger. I might add another layer of PVA though.

pics:

 

[HarasiElite]

Ok well today i've got a bit of bondo onto the helmet, (this is the part i hate the most). I found some difficulty applying the body filler- it is quite stiff and doesn't spread very well, is this because I've had the half used tub for 9 months? probably, I'm gonna need more. Anyway, the pics show you what i've done so far :wacko

pics:

 

[Bandiet]

Hi, what ration hardener to body filler are your using? I've also found that when I work with the body filler in cooler temperatures, it tends to be have a thicker consistency, but not really that it "gunks" up on me.


Sent from my iPad using Tapatalk

 

[Bandiet]

Sorry, meant to ask "what ratio" not ration...


Sent from my iPad using Tapatalk

 

[HarasiElite]

Sorry, meant to ask "what ratio" not ration...


Sent from my iPad using Tapatalk

My ratio is about right, one pea size hardener for a golf ball size amount of bondo. its been quite warm lately here in England too

I can only put the thickness of it down to the body filler being several months old and perhaps not the best for such detail. I'll just buy more and hopefully it will be fine!
I'm going try and get the rest of the 1st bondo layer done in the next few days.

 

[HarasiElite]

So I bought some new body filler and it was definitely easier to use! I got the whole helmet covered with one layer but I've done it very rough and the sanding is going to be a painful hell lmao, oh well :wacko Hopefully I'll start sanding soon and it will go well

pics:



The make do table is fairing well

 

[HarasiElite]

Got some sanding done today. Everything is rough, pics tell you everything :eek Deffo need another coat of bondo. I sprayed some primer on it because the primer is a weird yellow and it was almost finished anyway, other than that I don't know why i stayed primer on the helmet :wacko More updates whenever possible!

pics:

View attachment 338682

 

[HarasiElite]

Tidied it up a bit more. sanded etc, some filing for the eyes and stuff. Will apply second coat of bondo when my new box of disposable gloves arrive (safety first)

pics:

 

[HarasiElite]

Anyone have any idea how I would sand the inside of the cheeks? I can only think of resorting to an awkward sanding with sand paper; maybe that will be the only option? Any feedback is appreciated

 

[GavinSchulz2000]

Anyone have any idea how I would sand the inside of the cheeks? I can only think of resorting to an awkward sanding with sand paper; maybe that will be the only option? Any feedback is appreciated

At the moment I'm making a deathstroke mask and I just fold a peice of sandpaper up and use my fingers to get to all the hard to reach places like this one


- Gavin

 

[Bandiet]

Another RPF member - Glennh, gave my an awesome tip for the " hard to reach " area's that need to be leveled and smoothed. As Gavin said, fold your sand paper and try sand as much as you can, then place the helmet on its side so that the surface you are sanding is level and pour a small amount of resin into the area. The resin will self level and give a smooth finish. This tip has helped me a lot.

Hope it helps...


Sent from my iPad using Tapatalk

 

[HarasiElite]

Thanks for the tips guys! I've never heard of the resin idea but i guess i can try it out

 

[HarasiElite]

Well, Amazon are taking their time with the Gloves, but the Blue paint i ordered has arrived and it looks very good tbh, maybe a bit too dark?