Daft punk guy manuel helmet

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joshslayton

Well-Known Member

• Jun 17, 2014

• #1

Alright so im a pretty big fan of daft punk and for a while ive been wanting to make one of there helmets. Im a fan of every era of there helmet but really my favorite is the discover helmet. So that is what im going for here the discovery helmet with lights and all. I will be borrowing some techniques from volpins build and sorenzos build. So enough **** shat lets get down to buisness.

I first made a cardboard test base to see how the templates fit together. Once i got a feel of how they worked i cut them out of mdf




Then i cut out some foam blocks and glued them in black with smooth cast 320. Then i roughly carved out the shape sanding smooth with a palm sander








Then i coated the form with black acrylic paint. This is to protect the foam from the bondo layer.

 

Last edited: Jun 17, 2014

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joshslayton

Well-Known Member

• Jul 4, 2014

• #2

Back with an update

So now it off to the bondo stage. I went through 4 passes of bondo to get the smooth ness i wanted



I used a trick i picked up from thom over at sorenzo props by using a sanding belt to sand the helmet even


While that was off to dry from primer i figured its time to work on the ears.
The ears were cut out of 3 sheets of 1/4 mdf glued, and sanded into shape




Now those were close to being done i figured again to start on the frame around the helmet. Sculpting with epoxie sculpt






Its really roughy and bumpy but good thing about epoxie sculpt os that you can sand it!

 

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joshslayton

Well-Known Member

• Jul 4, 2014

• #3

Coverd the frame with more bondo to even it out







The ears were primed and sanded with fine sandpaper to seal the mdf then added some spot putty

 

made007

Sr Member

• Jul 4, 2014

• #4

Awesome, i used pepakura for mine, they dont sell that foam here
keep it up its looking great

 

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joshslayton

Well-Known Member

• Jul 5, 2014

• #5

Did some refinement with more epoxie sculpt and then added some spot putty








Now time to make the small ear piece. Since i dont have a lathe i improvised and used pvc pipe, styrene and you guessed it epoxie sculpt

 

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skint

Active Member

• Jul 5, 2014

• #6

On my ears I used some plastic shot glasses, they had just the right slope.
Now as for the lights, make sure you have accounted for the extra room inside the helmet for them. Volpins customer was quite tall so the helmet was larger, also the ear circuit patterns are not accurate. You can always spot someone who just took his ear circuit as reference.

 

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joshslayton

Well-Known Member

• Jul 5, 2014

• #7

skint said:

On my ears I used some plastic shot glasses, they had just the right slope.
Now as for the lights, make sure you have accounted for the extra room inside the helmet for them. Volpins customer was quite tall so the helmet was larger, also the ear circuit patterns are not accurate. You can always spot someone who just took his ear circuit as reference.

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The visor is pretty large surface area so i think ill have enough room for the lights. I plan on replicating the middle led matrix as well. As for the circuit ears im not sure if ill be able to replicate them. I could carve them out with a dermal but im not sure it will come out as clean. But i think i can figure somethin out

 

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joshslayton

Well-Known Member

• Jul 6, 2014

• #8

Little bit of an update. I sanded the frame more even the whole thing was looking a little uneven and also trimming around the ears to fit them better



And sanded the little ear piece so it fits nice and snug in the other ear piece thing




Still needs some work around the visor looks a little bumpy

 

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skint

Active Member

• Jul 8, 2014

• #9

Sorry I dont have a pic but i was able to dremel out the circuits on my ears. I printed the pattern to scale and stuck it on some clear PTEG plastic (probably doesn't matter, just what I had lying around and I found custom wood wasn't strong enough). I used a routing attachment on the dremel with 2mm bit, clamped a straight piece of wood to the bench as a guide to keep the lines straight. I dry tested each pass to check my alignment then fired up the dremel plunged down at the start of the circuit and stopped at the end of the line. All the lines are straight so it's not too bad, you just need to reposition it for each line.

 

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joshslayton

Well-Known Member

• Jul 10, 2014

• #10

Looked at some reference pics and it turns out that the back panel needs to stick out a little more so i glued some styrene and added some bondo




And then added more bondo to refine the visor

 

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skint

Active Member

• Jul 23, 2014

• #11

found a pic of my dremel routed circuits

 

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joshslayton

Well-Known Member

• Jul 30, 2014

• #12

Been a while since an update. Been mostly looking at reference pics to get a feel of the real helmet. So i widened the chin and raised the back of the ears




Of cores it looks ugly right now ill sand and fill it to be smoother

I also got a chance to work on the handplates to go along the helmet.
These were cut out of 3/4 MDF and then shaped and sanded to shape

 

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Taylor Jean

Well-Known Member

• Jul 30, 2014

• #13

Using MDF for the hand plates is a new idea, looks perfect! How's the size of the helmet do you think (depends on your height and I guess)? Also, are you considering the removable back piece?

 

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joshslayton

Well-Known Member

• Aug 2, 2014

• #14

Small update

I glued in the ears with smooth cast and added more bondo to the visor to shape it more. Still feels like itll need more but we will se once i sand it. I also added some spott putty.

 

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joshslayton

Well-Known Member

• Aug 2, 2014

• #15

Taylor Jean said:

Using MDF for the hand plates is a new idea, looks perfect! How's the size of the helmet do you think (depends on your height and I guess)? Also, are you considering the removable back piece?
View attachment 355594View attachment 355595

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I think i got the size pretty good. Im taller than guy really is so im sure itll look a little off when people see a tall guyman walking around. I ask my brother to photoshop te helmet over my head to get a feel of what the size will be

Of cores the sizing in the picture isnt perfect but its close enough

As for having a removable back tho i havent really gave it that much thought. Im really going for the human after all helmet with the discovery leds. But i dont know i might just consider doing a full replica of the discover helmet with backpack and everything

 

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joshslayton

Well-Known Member

• Aug 4, 2014

• #16

Small update again just regular ole sanding on the helmet nothing special




But the handplates on the other hand i got to vacuum form them today dosent seem that much but it was fun to do. I vacuum formed them with .060 styrene sheet. The first pull the molds moved a little but on the second it was a whole lot better

 

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joshslayton

Well-Known Member

• Aug 6, 2014

• #17

heres a video of me vacuum forming the handplates

 

Last edited by a moderator: Nov 8, 2018

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joshslayton

Well-Known Member

• Aug 6, 2014

• #18

Back!

I finally got around to molding one of the ears so i casted one then glued them to the helmet
View attachment 359410
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All this helmet needs is a little spot putty then i think o can start prepping this for rubber

As for the gloves i cut, trimmed, and sanded them to shape. 3 hours later





Testing on an old glove i had laying around

Then the handplates were to be prepped for chrome. Painted in a glossy black. Kinda like the loom of it tho

 

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Taylor Jean

Well-Known Member

• Aug 6, 2014

• #19

Those look great! You got the visor spot on too, can't wait to see the first cast. :cool How tall are you by the way?

 

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joshslayton

Well-Known Member

• Aug 6, 2014

• #20

Taylor Jean said:

Those look great! You got the visor spot on too, can't wait to see the first cast. :cool How tall are you by the way?

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Thanks mate. Im 6"0 tall im not sure how tall guy is in real life but hopefully it wont be a problem