Daft Punk Thomas Bangalter helmet build - FINAL p.20!

[Volpin]

The powers that be have asked me to split my massive Daft Punk thread into two parts. From here on out, this one will serve as discussion for the silver half of the techno chrome-dome duo, Thomas Bangalter.

(pic is of the final result - for more shots, visit page 20!)

I completed the other half of Daft Punk in July of 2010. Seeing as how you can't leave a pair half-finished, I've decided to start building Thomas' helmet as well.

Read about that build here

So, my process has not benefitted over the past year or so from any elegance, but I'm hoping this will still get the job done. Thomas START!

I started out by drafting the helmet in Illustrator, then printing to scale.

Pattern Drafting onto 1/4" MDF:

These are the component pieces...

...which forms this structure. The idea here is to sculpt the main dome of the helmet first, then add the visor and front chin at a later time.

I had a crapload of insulation foam laying around from earlier projects, and seeing as how I've vowed to never use spray foam again as long as I live, the pink foam get its shot at making the form. I'll be sanding this to shape once all the glue has set up.

Here's hoping this one won't take me another 17 months to finish...

 

[TheNickFox]

re: Daft Punk Thomas Bangalter helmet build

It may take some imagination at the moment to see the dome in a pile of insulation foam, but I can only say it's great to see this project finally begin!

If this is anything like your normal work, I'm sure it will be awesome.

Now I feel like I need to hurry up on my own Thomas build before you catch up. :lol

Can't wait to see how this all pans out.

...and how many future Thomas builds will use MDF profiles and insulation foam thanks to this.

-Nick

 

[Volpin]

re: Daft Punk Thomas Bangalter helmet build

...and how many future Thomas builds will use MDF profiles and insulation foam thanks to this.

Every time I see some poor guy start out building Guy with spray foam and illustration board, i feel a twinge of guilt. That is, by far, the worst way I can now think of to build that form.

To anyone thats done it: I am so, so sorry.

 

[Millsman163]

re: Daft Punk Thomas Bangalter helmet build

Every time I see some poor guy start out building Guy with spray foam and illustration board, i feel a twinge of guilt. That is, by far, the worst way I can now think of to build that form.

To anyone thats done it: I am so, so sorry.

Really? I thought that despite being really time consuming it was a very useful way to do it. I do however think the new way is a little more efficient though, haha. I can't wait to see how this one plays out.

 

[Agent RayBans]

re: Daft Punk Thomas Bangalter helmet build

"This is like IKEA for Daft Punk." I nearly spit ice tea all over my monitor!

I can't wait to see more progress, this should be a fun ride.

I think I've asked you a few times now, but are you scaling this to be larger like your Guy-Man was, or is this going to be a little more "normalized" in size?

Keep up the good work!

 

[Laamberry]

Re: Daft Punk Thomas Bangalter helmet build

Going to be eagerly watching >:] You've put it in my head that I really need my own Guy helmet...so it's just dumb luck that I searched for the thread today and you had started this one for Thomas! I'm sure it'll turn out great as usual.

 

[juntari]

Re: Daft Punk Thomas Bangalter helmet build

Why do you say spray foam was a mistake? I started using spray foam to fill in the gaps (with the main shape made from foam core) after seeing your build thread and its always worked pretty well. Do you mind explaining why you don't like that method?

 

[Alan Castillo]

Re: Daft Punk Thomas Bangalter helmet build

It may take some imagination at the moment to see the dome in a pile of insulation foam, ...

As Michelangelo said "I saw the angel in the marbel and merely carved until I set him free"

Nice start Volpin :thumbsup

 

[Risu]

Re: Daft Punk Thomas Bangalter helmet build

I'm on the same page as Nick, I need to get back to working on my Thomas helmet! This is looking good already, can't wait to see how it turns out. Are you going to go all out with the lights and everything?

 

[Ares5000]

Re: Daft Punk Thomas Bangalter helmet build

Hey Volpin, amazing work will soon follow I'm sure of it!

I started a pepakura Thomas helmet that is currently in the OCD sanding phase yet again. If you wanted to try that let me know, I've got a plotter that can cut out a .PDO helmet in a few minutes.

I've also found this kit that looks fairly straight forward for wiring a 5x24 Thomas LED display: NerdKits - The LED Array Kit

I'm still trying to figure out just how many LEDs are in the TRON Thomas helmet...

 

[Volpin]

Re: Daft Punk Thomas Bangalter helmet build

Why do you say spray foam was a mistake? I started using spray foam to fill in the gaps (with the main shape made from foam core) after seeing your build thread and its always worked pretty well. Do you mind explaining why you don't like that method?

Spray foam isn't really sandable. You can try hacking at it with some 60 grit, but ultimately you're limited to carving. Its also not dense enough to keep a uniform shape and can collapse in on itself when you put a bunch of weight (clay) on top of it. I find the pink foam much more versatile.

Also, i had it laying around, so it was free.

I started a pepakura Thomas helmet that is currently in the OCD sanding phase yet again. If you wanted to try that let me know, I've got a plotter that can cut out a .PDO helmet in a few minutes.

I've also found this kit that looks fairly straight forward for wiring a 5x24 Thomas LED display: NerdKits - The LED Array Kit

Thanks for the offer! I have a half-made Thomas pep helmet, might finish it just for scale reference, but pep and I just don't get along. As for electronics... well i'll cross that bridge when i get to it. Should be fun.

Progress! See the dome now?

Started out carving with a coping saw, then used an orbital sander with some 60 grit to refine the shape. Probably took a bit more off than necessary, but this will need to be built up with bondo anyways to get things exact.

front 3/4

rear 3/4

A trick I learned a little while ago for "sealing" pink foam is urethane casting resin. I tinted some smoothcast 300 and brushed it on top of the foam to give it a tough, chemical resistant shell for the sculpting process

First coat

3 coats dried

I'm pretty confident with where it is now. Think I'll toss it in some rubber then open up a JY thread. Sound good?

Seriously though, things always look so ugly at the beginning. Hopefully it'll look like something more than a ball of resin soon.

 

[juntari]

Re: Daft Punk Thomas Bangalter helmet build

What did you use to tint the resin? I'm always tempted to use food coloring but I could never get a clear answer to if it worked or not

 

[Crix]

Re: Daft Punk Thomas Bangalter helmet build

Harrison, I'm sure you'll end up making this look effortless as always. :lol

 

[Charles Kline]

Re: Daft Punk Thomas Bangalter helmet build

Your awesomeness encourages me to build awesomeness of my own.

Looking great so far! :thumbsup

 

[Gorgot3000]

Re: Daft Punk Thomas Bangalter helmet build

i love your idea to use the mdf pattern to make the right form of the helmet

 

[MrSinistar]

Re: Daft Punk Thomas Bangalter helmet build

Unbelievably awesome, Harrison! Can't wait for more progress pics!

 

[Agent RayBans]

Re: Daft Punk Thomas Bangalter helmet build

I just came across this picture as a result of a chart I made that was published over on Gizmodo.

The guy who posted this says he knows one of the guys who made the original helmets, and posted this picture as proof. I have never seen this picture before and though it was worth posting here!

***Edit

And here's another!

 

[Risu]

Re: Daft Punk Thomas Bangalter helmet build

I may be completely off base here, but did Red Bull exist when the first helmets were made?

 

[Charles Kline]

Re: Daft Punk Thomas Bangalter helmet build

Red bull was created in 1987 in Austria, it entered the US market around 1997

 

[Agent RayBans]

Re: Daft Punk Thomas Bangalter helmet build

I may be completely off base here, but did Red Bull exist when the first helmets were made?

These pictures that have just surfaced also match up with ones that have been around for quite some time, released through LED FX's website:

I thought the same thing though, "Has Red Bull really been around that long?"