Carbon Fiber Halo 4 Master Chief Helmet

[mxer911]

One of the benefits of working with carbon fiber is since you have a fairly significant cure time, it gives you the ability to tackle multiple projects at once.

So here's project number 3. A carbon fiber Halo 4 Master Chief helmet.
This project started as a casting that was purchased from a member on this forum. The helmet had a lot of great detail work, however due to the nature of carbon fiber and what it can do, I had to remove some of the small features.





Next I started by wrapping the top right in carbon fiber. While the weave of 2x2 twill carbon fiber it typically pretty tight, it is still ideal to put down a black base coat of epoxy resin first, as this will help to hide any spots where the carbon weave separates slightly.

While you can use the black base coat as your tack layer to hold the carbon fiber in place, I opted to let it dry and then use 3M spray adhesive to hold it in place. This allows me to work along the shape without worrying to much that it is going to touch the tacky layer somewhere I don’t want it to and get stuck…make sense?

 

[mxer911]

After letting the spray adhesive do its thing over night, I then hit the carbon fiber with its first layer of epoxy. Not too much though, just enough to wet out the fabric. Now we’ll leave this to cure for atleast 24 hours before moving on to the next side.



Much like the first side I do the black base coat, then use spray adhesive to position and hold the fabric in place. It important that you give yourself extra carbon fiber to work with because if you have too much you can trim it, but not enough and well, you get the idea.







Now I lay the resin to the second side of the helmet. You are now at the part where you need to start creating some clean seams which can be tricky. My trick is to lay the resin, allow it to cure for about 6-8 hours and then use a scalpel to make clean cuts. At this point the carbon fiber should be slightly tacky however it will now hold it’s shape and allow you to make those clean lines without disturbing the weave.

 

[mxer911]

At this point I’ve cut out the eye port as I’ll need access to the inside so that while wrapping the bottom portion I can fold the carbon fiber inside. In this picture you can also see the black epoxy base coat.



When working with a lot of peaks and valleys it’s important that you only spray the adhesive directly where it’s needed and work your way a crossed the part. Cover the whole area and you find that the fabric will “accidently” lay down on an area, get stuck, and you now have to remove the whole layer and start again (keep in mind when I say start again I mean with a new piece of carbon fiber, as the first one will be junk). Not good.

That being said, if you take your time good results are possible, and you’ll be surprised at what shapes the carbon fiber will take.

 

[metal wood]

carbon fiber is some cool stuff, never experimented with it, not even sure of the costs. way cool to watch you work with it though.

 

[Maddhatter3]

Should come out to be a nice looking piece. Very interested to see the final product.

 

[FateLazarus]

This is very interesting. I had a carbon fiber hood on my car back in the day but I had no idea that the material could be molded into such an intricate shape. I can't wait to see how this turns out.

 

[MxRacer476]

Very cool....

 

[Mike J.]

What purpose does the green tape serve?

 

[mxer911]

Thanks everyone. I'll be honest I was a little nervous regarding whether the carbon fiber would take the shape, but quite happy that it worked out.

What purpose does the green tape serve?

The green tape protects the previously laid carbon fiber from the spray adhesive, as well as gives me a guide to how far I can trim the carbon fiber back.

 

[MxRacer476]

I think I can see and hear the mob gathering pitch forks, and torches.... something about demanding more pics...

 

[mxer911]

I think I can see and hear the mob gathering pitch forks, and torches.... something about demanding more pics...

Ask and you shall receive. With the resin cured, here's a few pictures of the helmet with the one side entirely covered in carbon fiber. Now I'll finish off the other side, then its time to start building up the layers of resin.

 

[MxRacer476]

Pretty sweet fellow MX'er!! I must say... I cannot wait for the finished product! I have quite a bit of 2x2 twill laying around hmmmm

You gonna finish it gloss, or matte?

 

[raif79]

Have you thought about doing an entire suit in carbon fiber?

 

[MooMooEgg]

This is a really cool concept and I love the way it looks. It's just a shame that the details of the hlemet are lost. :cry

 

[RobertH]

Looking great so far...very interesting.

Rob

Sent from [location encrypted]...somewhere on the Tharkside of Barsoom

 

[MxRacer476]

This is a really cool concept and I love the way it looks. It's just a shame that the details of the hlemet are lost. :cry

Details wouldn't be lost if it was finished in a MATTE effect, as the gloss finish amplifies the weave detail... Therefore crisp shapes and lines would pop under the MATTE surface... Agreed tho, that is why I asked his finish intentions

 

[mxer911]

Have you thought about doing an entire suit in carbon fiber?

Thought about it and it’s something I’d love to do in the future, however I simply do not have the time to take on a task of that size. One day though.

Pretty sweet fellow MX'er!! I must say... I cannot wait for the finished product! I have quite a bit of 2x2 twill laying around hmmmm

You gonna finish it gloss, or matte?

Thanks fellow MX’er! Customer has requested gloss, so gloss it shall be. I’m personally not a fan of matte finish, however to each their own.

This is a really cool concept and I love the way it looks. It's just a shame that the details of the hlemet are lost. :cry

I wish I could pick up all of the small details however just not possible so had to make a compromise.

Details wouldn't be lost if it was finished in a MATTE effect, as the gloss finish amplifies the weave detail... Therefore crisp shapes and lines would pop under the MATTE surface... Agreed tho, that is why I asked his finish intentions

Even if it was finished in a matte finish there would still be details that simply couldn't be captured by the carbon fiber, though I will agree that you can achieve crisper lines with a matte finish.

 

[mxer911]

Here's a quick video after just laying the second coat of resin on the Master Chief helmet.

 

[MxRacer476]

Awesome!! As well as on IronMan... What are you charging?

 

[mxer911]

Awesome!! As well as on IronMan... What are you charging?

Sent you a message on Facebook :thumbsup