I had been posting in that thread but don't want to clutter it up with a work in progress.
I decided that it was about time I experimented with Pepakura, and that the Dredd helmet seemed like a good base. Here we go!
Rather than paper, I build this out of 0.040 styrene, assembled with tape on the outside wherever possible. The idea was that this would make a shell that could be peeled off later.
Once it was assembled, I added some support strips to a few areas and plugged up the face opening with masking tape.
Once it was ready I sprayed the inside with mold release and slush cast Smoothcast 325 on the inside to a wall thickness of about 1/4"
Then the peeling began!
After a fair bit of sanding I got here:
Started reshaping things... closing up the face opening a bit, reshaping around the eyes, and sanding more.
More iteration, and I realized the bottom was too curved. I fixed that up with heat gun and bondo:
I decided that it was about time I experimented with Pepakura, and that the Dredd helmet seemed like a good base. Here we go!
Rather than paper, I build this out of 0.040 styrene, assembled with tape on the outside wherever possible. The idea was that this would make a shell that could be peeled off later.
Once it was assembled, I added some support strips to a few areas and plugged up the face opening with masking tape.
Once it was ready I sprayed the inside with mold release and slush cast Smoothcast 325 on the inside to a wall thickness of about 1/4"
Then the peeling began!
After a fair bit of sanding I got here:
Started reshaping things... closing up the face opening a bit, reshaping around the eyes, and sanding more.
More iteration, and I realized the bottom was too curved. I fixed that up with heat gun and bondo: