Daft Punk Thomas Helmet build

The original Pep.
You'll notice:
A: its 100% a yoga mat.
B: this is my very first attempt of this type of project. (never built a foam anything!)



The below image is of weeks of filling and sanding.




After research, my jaw and chin where not long enough.
Also, the brow just wasn't playing ball.
So I decided to laser cut the original Pep file on .5mm styrene.
I cut off the front of my original helmet and stuck my new styrene front.
Resulting in a better front altogether..

I've filled the helmet with foam, to strengthen the entire unit.

A small test of my vacuum former for the ear parts (these are not accurate! merely a test for size and my machine)

A quick mockup of the internal visor light cage.
Sadly, this isn't big enough... the height is spot on, the diameter is too short



I cant seem to get vent locations to fit my pep file cut, so I'm just using this pep file and hope for the very best.


This picture does not do the cutting justice.
It's spot on, though the picture makes it look like a lot of hacking.
The vent holes actually took me the best part of 2 hours the cut perfectly.



Plenty of views but no input on this.
This is my very first attempt of this type of project.

Man that is some good looking work! Keep it up.

Have you decided on what you're going to paint/ chrome it with yet?

Good question.
Once I've cast it. I may make 2 versions, Chrome and Black.
Chrome version will have the internal led lighting.
Black version will have the external red lighting.
I'm doing both Thomas and Guy helmets.
I saw a guy wearing a helmet at a recent comicon and immediately said to my son, "bought on ebay!"... they are so identifiable!
This an amalgamation of about 6 different files i have found, with some major adjustments by myself.
There is a top "lip" missing on my visor... will i add it?... i don't know yet.

Yes you can see out with no problem.
Whilst not an exact replica, this set up cost £6 very pretty and bright and is powered by a 7.2v battery!