Build update:
Set about altering the back panel of this lid. As mention earlier in the thread, it didn't stick out enough and was at an inaccurate angle. I placed a piece of material in the centre to higlight the angle needed and the distance it need to extend.
I cut a piece of styrene and used it to create the right curvature. i filled in the gap with shaped foam. Once i was happy, I cover the whole thing with filler and sanded it back.
then sanded back the old incorrect piece of the helmet.
Same process for the back panel, foam covered with filler and sanded back.
very happy with the result.
When I applied the paint it was obvious that that rear panel is a little bulged. This isn't too much of a problem as it will be completely removed from the castings and replaced with a completely new piece of material that will hold the coloured wires.
Set about altering the back panel of this lid. As mention earlier in the thread, it didn't stick out enough and was at an inaccurate angle. I placed a piece of material in the centre to higlight the angle needed and the distance it need to extend.
I cut a piece of styrene and used it to create the right curvature. i filled in the gap with shaped foam. Once i was happy, I cover the whole thing with filler and sanded it back.
then sanded back the old incorrect piece of the helmet.
Same process for the back panel, foam covered with filler and sanded back.
very happy with the result.
When I applied the paint it was obvious that that rear panel is a little bulged. This isn't too much of a problem as it will be completely removed from the castings and replaced with a completely new piece of material that will hold the coloured wires.
Next up, the painstaking task of perfecting every blemish, and there are always far too many 
the main one was this hollow in the visor, which I have no idea how i missed??
The band at the top of the lid was a mere 1mm too low at the very top. A very useful trick for a quick, even build up.
I stuck strips of 1mm styrene down to the band, then filled in between them. The styrene acts as a marker for sanding, once the styrene become visible you know to stop sanding. once I had it nice and smooth, i removed the stryene and fill the gaps.
the main one was this hollow in the visor, which I have no idea how i missed??
The band at the top of the lid was a mere 1mm too low at the very top. A very useful trick for a quick, even build up.
I stuck strips of 1mm styrene down to the band, then filled in between them. The styrene acts as a marker for sanding, once the styrene become visible you know to stop sanding. once I had it nice and smooth, i removed the stryene and fill the gaps.
Spengler28
Active Member
WOah im totally speechless, :O i absolutely want one!!!
EZBSVS
Well-Known Member
Absolutely beautiful. I've been working on my own Guy helmet, but yours definitely blows mine out of the water. Great job cleaning it up, getting all those small areas clean and precise must have been a pain, but it all pays off in the end.
Can't wait to see how the mold turns out! Good luck!
i
Can't wait to see how the mold turns out! Good luck!
i
Rabid Irish
Active Member
WOW. Love it! Fantastic work.
So I realised that its been nearly 9 months since I last used my silicone, and have got quite a bit left on the tubs. Was a tad worried that it might be past it sell by date, so rather than potential waste alot of time, I've done a small sample piece. Looking good so far, which is a relief, that **** be expensive!
This will also give me a chance to experiment with the reg keys. Having had bubbles under where the reg keys were placed in my last mould i'm anxious not to repeat this. Last time I placed fully cured reg keys onto a wet layer of silicone, I think it was my second coat, the first being a thinned down coat to catch the details.
My thinking this time round is to wait until i've applied all the coats, then stick the reg kegs on, perhaps even when they are still a bit tacky?
Anybody got any thoughts?
Also, one piece mould, or should I split it??
Decisions decisions
This will also give me a chance to experiment with the reg keys. Having had bubbles under where the reg keys were placed in my last mould i'm anxious not to repeat this. Last time I placed fully cured reg keys onto a wet layer of silicone, I think it was my second coat, the first being a thinned down coat to catch the details.
My thinking this time round is to wait until i've applied all the coats, then stick the reg kegs on, perhaps even when they are still a bit tacky?
Anybody got any thoughts?
Also, one piece mould, or should I split it??
Decisions decisions
i put my reg keys on top of the ''last coat'' and that seemed work fine. I smeared a nice dollop of thickened silicone on the bottom of each key and gently pressed them on in a small circular motion to work out any bubbles. Worked great, shame the rest of my silicon mold was too thin to hold it's shape correctly in the mold.
Good luck with your mold, am really looking forward to seeing this being worn
Good luck with your mold, am really looking forward to seeing this being worn
Rabid Irish
Active Member
I would do a one part silicone mold with a 2 or 3 part outer jacket. The mold might not last as long as a 2 part mold, but you will probably get a better quality cast out of a one part mold. You also wont have to worry about seam lines and having to clean them up. I did a 2 part mold on my Thomas helmet and it is nearly impossible to line the 2 silcone molds back up to get a perfect seam line. It almost always requires a lot more clean up. Just my two cents.
Rabid Irish
Active Member
How's the moulding going?
Casting complete
Think you all know the process by now, so here's a load of pics. Any questions, feel very free to ask.
(need to get a more professional makers mark)
I spent a long time deliberating what sort of mould I should do, I went with a one piece simply out of impatience. I really couldn't stand the thoughts of having to spend any more time working on this lid. I NEEDED a cast pulled ASAP!
The mold came out perfect (well as perfect as a mold can be)
And the cast came out amazingly!
Sooo, what do you think??
Think you all know the process by now, so here's a load of pics. Any questions, feel very free to ask.
(need to get a more professional makers mark)
I spent a long time deliberating what sort of mould I should do, I went with a one piece simply out of impatience. I really couldn't stand the thoughts of having to spend any more time working on this lid. I NEEDED a cast pulled ASAP!
The mold came out perfect (well as perfect as a mold can be)
And the cast came out amazingly!
Sooo, what do you think??
Spengler28
Active Member
Outstanding!!!!!!!:behave:thumbsup
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