Daft Punk Thomas Build

Flapjack

New Member

• Nov 23, 2013

• #1

Hi All,
I am new to the prop building world. That being said, I need a little advice/direction on my current and second build. I have the helmet fiber glassed already, but I wanted to get the visor done before I do any bondo work on the outside. I cut out the fiber glass section and started using it as a template piece for heat bending the plexiglass. This is where I need the help: I need suggestions on how to get a good and smooth looking bend to the plexiglass. So far I've tried clamping one end to the fiber glass template and bending it with a heat gun, but I am having trouble getting a smooth consistent bend (i.e. there are weird straight parts on the ends but a good bend in the middle). Here is a picture of the mask before I removed the lens template piece, sorry not to have pics of the plexiglass piece so far, I will upload them tomorrow once I remember to take some.

 

J

Jack Martin

New Member

• Nov 24, 2013

• #2

Cant wait to see it, i finished mine quiet recently and took it to October London MCM

 

Flapjack

New Member

• Nov 30, 2013

• #3

Update:
So I’ve managed to fix the plexiglass bending problem for the most part… My thought on the next step is to permanently mount the tinting to the plexiglass (put a test stripe on temporarily to make sure the darkness on outside and visibility on the inside were ok). After, I was considering tacking it in place with hot glue then fixing it with silicone caulk to keep it sturdy long-term. Here is were I am looking for advice though, if I put in place earlier, I can tape off the lens and fill in any gaps with the lens and mask with bondo giving a clean finish. The negatives could involve the tinting peeling away later when I go to remove tape, or just general issues with sanding and painting.
Here are some pictures of the progress so far:

 

Last edited: Nov 30, 2013

Flapjack

New Member

• Dec 3, 2013

• #4

Did some sanding yesterday on the top dome. Added some more bondo to fill in low spots and got the rest of the face covered with a bondo base layer. Going to sand some more tonight and fill in other low spots and hopefully be able to get a thin coat on the ears.

Fun Fact about this helmet, building it as a gift with the deadline being Dec. 14th, but I plan on mounting a pair of Skullcandy GI's that I cracked to the inside. I took them down to the basic speaker and face plate with the mounting brackets for the padding. I think this will be a cool addition, to be able to jam out with some pretty decent headphones when wearing it. Also, help hide the cord, I am mounting the 3.5mm headphone jack in the back-inside of the helmet so you can run a cord extender to it when you actually want to listen to music, otherwise it will remain unseen.

 

Flapjack

New Member

• Dec 8, 2013

• #5

more sanding today. Focused on the ears mostly. nothing really to exciting to report. Working on re-wiring the headphones on the side. Once I actually get them sanded down and fitted for the inside I will snap a few pictures. Apologies for being lazy with pictures thus far, going off my jenky camera on my phone.

 

Crank729

Sr Member

• Dec 8, 2013

• #6

Nice progress, helmet looks good!

 

G

goezzmeister

New Member

• Dec 9, 2013

• #7

with regards to the bending:
cut out the plexiglass (sand the edges) and put it in a pre-heated oven (approx 150 degrees celsius). to be sure just put it on a baking tray so that the middle has possibilities to bend. after a few minutes you will see the plexiglass bend.... leave it for a few extra seconds to ensure it bends sufficiently. as soon as you get it out you'll have to bend it into shape over a moulding with the same curveature. apply pressure for a minute and your done!

with regards to applying it before bondo... not sure whether that will turn out good... a lot of room to scratch the surface. at least make sure you duc tape the front so it won't get scratch.

with regards to the ear pucks: there a some really nice, 3d printed, ear pucks from shapeaways. they really finish it off!

seems like you are on a tight deadline! I am already working on my Thomas for approx 6 months hahaha... good luck!!!

 

Flapjack

New Member

• Dec 9, 2013

• #8

Whoo actually got my camera to work and send pictures to my computer (it's not a smartphone)
Here is a shot from the top, the rim still looks a little wonky to me. Going to touch it up a little more with bondo and try to round it out better tomorrow.

Shots of the side, the ears a still a little screwy. more Bondo and sanding tomorrow here to... well once again round it out.

And one other picture

 

Flapjack

New Member

• Dec 10, 2013

• #9

Sanded and patched in a few holes tonight then re-painted. Tomorrow I am looking to focus on the ears primarily to get a little better look (I sadly realize it will not be perfect by Saturday... but I can try). Goal is to get the ears to a good point and rest of pin holes finished and then primed in black. Thursday I am looking to get a coat or two of the chrome on and Friday do any final touch up work on the paint and then mount the headphones into the interior. For that part I am using Skullcandy G.I.'s which, with minimal sanding, fits pretty perfectly inside having the padding run run our about a 1/4 inch to help secure/cushion the helmet.

Pics

 

WakingGiants

New Member

• May 12, 2014

• #10

Dude, this looks legit! Good work.