That'll be a separate sales thread once I've made more progress on the prototype. First I've got this lady and the Flametrooper helmet to knock out.
UPDATE: I made the molds over the weekend. Here's a stack of progress pics...
For this particular helmet, I decided to go with a matrix mold. This means that the prototype was mounted to a board and wrapped in plastic wrap, then covered in clay like so:
The clay determines the final shape of the rubber jacket. But first I make the mothermold. Here's the first half laid up:
And the second half:
Once the fiberglass mothermold had cured, it was removed from the helmet prototype and the clay was cleaned out:
Then the prototype was cleaned up a bit more and sprayed with a generous coat of release agent:
Then I mixed a batch of thickened silicone to pack into any overhanging areas that would trap bubbles when pouring rubber:
Once that was done the mothermold was put in place again:
Then the edges were sealed all the way around with hot glue:
Finally, the whole mothermold was filled with silicone:
It was still a bit soft when I checked first thing this morning, so it'll be a few hours before I can demold everything and pull the first kit. But unless something goes wrong it'll happen today.
Once I post pics of a cast kit, I will no longer be offering the pre-order price. So if you want to save yourself a few dollars on this helmet, don't delay.
If anybody else wants to get in on this run, please post here and I'll PM you with payment details.
