A little help with fiberglass

Yes, you can, but don't. It will mean a lot more work in the end. You will have to bondo and smooth it after you glass over it.

I believe that he use sheet stock to build that Master Chief, either styrene, or poster board.

If you are going build the helmet as he did: better to make a mold, and lay the fiberglass into the mold.
 
What if I sculpted the helmet in clay? Could I then make a ultracal mold then cast it in fiberglass? What would be the best way to go about this?

Soooo many questions :D
 
I am interested in this as well... He did a great job with it, it looks awesome. For some reason I dont think sculpting would be the answer for me... paintball helmet base would be.
 
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