Daft Punk Guy Helmet: Final p.16, TRON p.20

Volpin, how did you cut the perfect circles out for the ear puck windows? (how did you cut a perfect circle of plexi glass to go into the puck)
 
MrPinski said:
Volpin, how did you cut the perfect circles out for the ear puck windows? (how did you cut a perfect circle of plexi glass to go into the puck)
Click to expand...

If you can find a hole saw with the correct inner diameter and without a guide drill (so you'll keep the puck), that is the easiest way I know of.

 
There has to be another way... I don't think that the puck thats cut out of a 1 3/4" bit will fit into the hole thats cut from the 1 1/2" bit...
 
wish I had an easier way to do it, but I just traced a circle on some PET plastic, rough cut on my bandsaw, then hand trimmed it with a dremel to fit.
 
I've been admiring your work since your build video came out, and I've decided to finally bite the bullet and begin the long and difficult process of making my own.

Since I'm a much better draftsman than I am a sculptor, I'm going to be drawing up .25" cross sections off of plans and then stacking pink foam ala your Thomas build cut into those cross sections and use bondo to fill in the corners and smooth.

Since the whole idea is to limit the amount of freehand carving I have to do with an accurate initial drawing, I was wondering when sizing the mold in relation to measurements of the wearers head how much space you factored in for the helmet thickness, electronics, lining and comfort room? I'm guessing in the realm of two inches total widthwise and three lengthwise?

Edit: I did a hand sketch and cut out some cardboard outlines and with 1.75" extra width and 3.5" length looks like it'll probably be sufficient, but it'd be good to hear from any of you fellows that's made one so I don't get the electronics on the finished helmet and realize my giant dome doesn't fit. :)
 
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Hey volpin, how did you mount your Dremel to the work bench when you were grinding down the finger plates??? I have an idea to make a set of gloves using a different method and need to do the same setup to you had going on.
 
I just took two clamps and clamped the tool itself to one of the steel legs on the table. Had to make sure not to clamp too tight, as the pressure would flex the plastic dremel casing and make the motor hit the sides of the enclosure.
 
Thanks man. Imma give it a shot soon. I found a shop here in downtown LA to do the laser engraving for $20 total. It's a little more out of the way than the shop that's 3 miles from my house, but they wanted $25 for set up fees and 70 for materials and labor.
 
I watched your build up of the wire-head Guy helmet and I was impressed, and I am even more thrilled that you are doing the Tron helmets! You do amazing work!
 
I have followed your blog for years, and felt obliged to comment on your RPF threads as well :) these are excellent, excellent work, and I cannot wait to see the full version of the TRON Guy-Man helmet :) I'm not even that big a fan of daft punk, but I have gained a new appreciation for the amount of work that has gone into these helmets since reading this thread! :D
 
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