LOTR Witch King War helmet - from scratch...WIP

ob1al

Sr Member
After finishing my Uruk Berserker helmet, I couldn't resist making a start on my next LOTR helmet project today, after a big family Sunday lunch and watching the footie.

My daughter and I found some old cardboard boxes and went to work.

Here's where we are at so far. This sucka is BIG man!

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Oh, the irony! Look, we made some of it from an Onion RINGS box! Gettit, RINGS! lol....

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It's only just taking shape, but it's going to be really big and cool when I've finished - look at the size of that thing!

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More pics to come very soon....

Al
 
Thanks BB!

OK, the last pics for today.

I have modified the proportions a bit and started adding some of the detailing to the mask.

Remember, this is just a basic 'skeleton' frame to work on, all the real detail will be added later with resin, fiberglass, and so on.

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That's all for today, hope you all enjoy seeing the project come along.

Al
 
Thanks all for the encouragement.

OK, tonight I've hardened up the cardboard frame with some polyester resin:

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I'm happy with the overall look and proportions, so the next step is bodyfiller to add the detail and really bring this build to life!

Al
 
I like this helmet design too, especially the evil-looking spikes (not on mine yet!).

Not much progress to report as I've been super busy today, but I did manage to get another good thick layer of resin on before work this morning and it's improved the look again, or at least smoothed things out a bit:

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Bodyfiller time next. Then spikes.

Al
 
Thanks.

I have a few hours spare today, so I've started the bodyfiller build-up.

Just when I got the helmet nice and smooth, now I have to mess it all up again with this gunk! But really, bodyfiller is great, so quick and easy to sand, I like working with it.

Here's a quick shot of the first bodyfiller layer going on:

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I'm using UPOL EXTRA polyester filler paste.

I'll build the shapes up layer by layer, then sand the entire surface down with a coarse grade paper. The original prop has a textured, hand-beaten and rough kind of finish, not all smooth and nice, which makes this job a LOT easier.

More pics later, gotta get back to it!

Al
 
The basis of the spikes - some 6" steel nails. These will make a solid base for the spikes and I'll sculpt over them with milliput to achieve the final shape..

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After an hour of sanding, I needed a break so I did a test fit on the nails...I'm pleased, they look badass!

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Now I have to get back to sanding...urg, my arm hurts!

Al
 
Cool build!
Quick question - at the top you mention fiberglass...are you going to be adding fiberglass, or did you just do the resin?
 
I originally intended to add fiberglass matt to strengthen the structure, particularly the large spike on top - but actually, the cardboard, 2 good coats of resin and bodyfiller turned out to be very strong, so I didn't need to use the matt.
 
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