Budget Mercury suit
- Thread starter N3rdyboy
- Start date
N3rdyboy
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Thank you very much! I appreciate your support!
N3rdyboy
Active Member
That's great! Thank you!
N3rdyboy
Active Member
Thus far on the helmet, something seems off I'm fairly certain that the size is right, but the top is too square (anyone have any ideas how to fix that?) so I'm kind of stuck for now. Here's some pictures compared to my reference photos. The X-wing helmet of mine is made from an old baseball helmet and if you ignore the Mohawk the helmet there and the mercury helmet have a similar shape, I have that on my helmet, just kind of wanted to point that out. Going to the ear-pads on Gordon Cooper's helmet they appear to be about an inch and a half, the distance from my ear to the edge is about 2 1/2 inches so maybe cutting the helmet down some might also fix the "dome issue"
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N3rdyboy
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Ok, break over. Back to work. I have been working this helmet and nothing, so I guess I'm going to learn to fiberglass. Need to save up for a bit, (especially with the holidays) so it may be quiet for a little longer. I figure since I have the fabric I should move on to adding the shoulder and knee "straps" I'll also make the legs more straight and less baggy. So during my break, I was at Disney World and one of my favorite rides being Mission: Space I noticed a few things in the pre-show that gave me an idea. The pre-show is you and your "flight team" being told by Gary Seines your jobs and mission on "your historic flight to Mars." Anyway in front of you are lockers with your space suits in them. When the suit is complete I'll make a version to store my Mercury suit in. (Better than it hanging up in your room I suppose!) alright that's all for now!
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N3rdyboy
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I will begin to see the "faux straps" on the shoulders and knees soon along with straightening the leg and making a better neck ring and helmet, but as of now this is how much I've spent
$11 tyvex suit
$23 fabric and thread
$9 for the air hose and connector
$20 for the zippers
$7 NASA patch
$12 for straps
Total spent as of 10/2/16
$82
$11 tyvex suit
$23 fabric and thread
$9 for the air hose and connector
$20 for the zippers
$7 NASA patch
$12 for straps
Total spent as of 10/2/16
$82
N3rdyboy
Active Member
Thanks! I would have loved to do that bit thats the first time I've been to Pigeon forge since I was 4! And even though it would be cool, a 5 hr drive for a picture might not be worth it, but thanks for the support! I'll have some pictures tomorrow on my progress!
N3rdyboy
Active Member
Based on what I have found out about the "baggyness" of my legs and shoulders, I'm being extremely cautious of how I proceed with the actual suit. In the meanwhile I have been searching how to make the helmet. First I went back to Tested.com to find how Adam's helmet and neck ting were made http://www.tested.com/art/makers/463885-making-bf-goodrich-mercury-mark-iv-helmet-part-1/ My foam isn't working, do I'm going to try slush casting. I originally wanted to try vaccuforming, but that's not currently an option. So I have begun to remake the helmet form, better and in one price, In this version I have more structural support so it should be more accurate.
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Have you thought about paper mache? I've seen some people get very smooth finishes with it. You could form it on a large balloon.
Fantastic build!
I purchased a Russian high altitude helmet as a precursor to building a merc suit at some point. It gives me significant detail about the neck ring and dimensions. You may want to consider the investment in one. It's a great display piece. They're pricey but the detail is fantastic - I may even repurpose the neck ring because the engineering is so well done:
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N3rdyboy
Active Member
Thanks! I think I had heard somewhere that somebody had done that for their Mercury suit. I'll definetly check out the neck ring. (I was dreading trying to make moving parts)!
N3rdyboy
Active Member
Thanks! If you would please! That would be useful and much appreciated!
Here are the pics I took - not sure of the helmet sizing. Ryan Nagata or A. Savage may know more about the variations in helmet sizing.
I measure the ring at 10.25" on the bottom of the ring and beveled up to 10" on the top of the ring. Interior ring is 8.75".
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The channel in the last pick is what the helmet locks into. I took a couple of pics of EVA foam I have. Regular workout mats are a hair too wide to sit in the channel easily. I bought some foam from TNT cosplay(clearance section) and the white stuff fit perfect and was able to slide easily without being loose. Here's a pic of the foam thickness and of the channel.
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