Captainyolk
New Member
Re: Daft Punk Thomas Bangalter helmet build
Ha! Too funny Harrison! Can't wait to see these LEDs in action.
Ha! Too funny Harrison! Can't wait to see these LEDs in action.
Daft Punk Thomas Bangalter helmet build - FINAL p.20!
Re: Daft Punk Thomas Bangalter helmet build
this needs a LOT of tweaking - thankfully my friend James Moss (James Moss | Web development, PHP and JavaScript) who is programming the matrix is already on solutions. He's said I should have some other test patterns and animations ready sometime next week.
Right now the matrices are illuminating out of order top to bottom, out of order left to right, and they should also be scrolling horizontally... All fixable in software, thankfully. Still a long way to go but it was a huge relief to see all the LEDs lighting up!
Video here
this needs a LOT of tweaking - thankfully my friend James Moss (James Moss | Web development, PHP and JavaScript) who is programming the matrix is already on solutions. He's said I should have some other test patterns and animations ready sometime next week.
Right now the matrices are illuminating out of order top to bottom, out of order left to right, and they should also be scrolling horizontally... All fixable in software, thankfully. Still a long way to go but it was a huge relief to see all the LEDs lighting up!
Video here
Agent RayBans
Sr Member
Re: Daft Punk Thomas Bangalter helmet build
Wow! Looks great all lit up!
Wish I could go to Dragon Con to see this in person.
Wow! Looks great all lit up!
Wish I could go to Dragon Con to see this in person.
ThreeFN
Member
Re: Daft Punk Thomas Bangalter helmet build
Now, see, you never should admit that the test pattern is wrong because something isn't right, instead you just say "I got tired of the old test patterns you see in everyone else's video so I decided I'd write this one." Everyone's none the wiser
Glad to see you're making good progress. Your speed of completion is forcing me to get off my sorry arse and spend some quality time with the weller. Ok, ok, not forcing me, providing good encouragement we'll say. I'm about half way through the second round of soldering, ie common anodes. If I'm completely naff and my arm doesn't give out I should 2/3 done by end of today.
It's a race to the finish! Except you're already done...
Now, see, you never should admit that the test pattern is wrong because something isn't right, instead you just say "I got tired of the old test patterns you see in everyone else's video so I decided I'd write this one." Everyone's none the wiser
Glad to see you're making good progress. Your speed of completion is forcing me to get off my sorry arse and spend some quality time with the weller. Ok, ok, not forcing me, providing good encouragement we'll say. I'm about half way through the second round of soldering, ie common anodes. If I'm completely naff and my arm doesn't give out I should 2/3 done by end of today.
It's a race to the finish! Except you're already done...
tekparasite
Member
Re: Daft Punk Thomas Bangalter helmet build
:lol I think seeing the work of others puts a jolt of encouragement to finish our own. Not to put any pressure on anyone, but I'm 'neck-in-neck' with Volpin in terms of finishing Thomas.
Now, if it comes down to quality of work.. well, I don't think I qualify in that race.. :lol It's all good!!!
:thumbsup
Hopefully this weekend I should see my matrix blinking!! :love
:lol I think seeing the work of others puts a jolt of encouragement to finish our own. Not to put any pressure on anyone, but I'm 'neck-in-neck' with Volpin in terms of finishing Thomas.
Now, if it comes down to quality of work.. well, I don't think I qualify in that race.. :lol It's all good!!!
:thumbsup
Hopefully this weekend I should see my matrix blinking!! :love
Muppo
New Member
Re: Daft Punk Thomas Bangalter helmet build
I'm stunned on how it is going. Its simply amazing how well all the pieces of the puzzle fits, great job Volpin.
Don't ask why but, somehow, I was thinking you'll use that Portal 2 song on one of your progress videos so I loled hard when I saw the led test.
Nice potato GlaDoS, by the way. My lil sis wants one now :lol
PS: Sure you read this so many times but I like to know how much do you ask for a single Thomas cast. Also a both helmets pack will be nice too
Regards.
I'm stunned on how it is going. Its simply amazing how well all the pieces of the puzzle fits, great job Volpin.
Don't ask why but, somehow, I was thinking you'll use that Portal 2 song on one of your progress videos so I loled hard when I saw the led test.
Nice potato GlaDoS, by the way. My lil sis wants one now :lol
PS: Sure you read this so many times but I like to know how much do you ask for a single Thomas cast. Also a both helmets pack will be nice too
Regards.
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Re: Daft Punk Thomas Bangalter helmet build
In doing more research (I know, MORE!) it looks like the "full LED matrix" helmets ALSO have 2 rings, but one of them is on the inside of the concave surface of the helmet.
Its impossible to get a bead on this stuff, I swear.
That said, I'm sticking with my "one ring of color" plan - the electronics are already taxing battery life, I'd rather not push it if I can afford to. Plus, there's so many variations - who's to say this isn't actually one of them?
This weekend, I messed around with some polyester resin and fiberglass cloth casting. I've had issues with chroming urethane before, as the baking/curing process can sometimes deform the pieces. The shop I've worked with has since figured out a way to rectify this for urethane helmets, but I felt that a little proactive measures on my part wouldn't be a bad idea.
Polyester resin and cloth will also make my cast piece very, very thin by comparison, and that gives me more wiggle room for mounting the LED matrix. I did some test fits in my mockup urethane casting, and the amount of material I'd need to remove from the visor area was making me slightly uneasy.
Here's a shot from the inside while the resin was curing:
The "X" marks are indicators where I've laid down a second piece of fiberglass cloth. This way I can make sure I don't skip any spots.
Finished results were pretty good for my first crack at this. A few areas where I missed layering, but these are smallish bubbles and can be taken care of with more resin or bondo after I've done some trimming.
I also made a set of ear pucks from polyester resin, and embedded a blind nut into the part. These will hold the outer ear against the clear disc and the circuitboard in place.
Things are picking up speed now, hoping to have the buckets ready for chrome by the end of the week.
The regular discovery ears have one ring of color:
In doing more research (I know, MORE!) it looks like the "full LED matrix" helmets ALSO have 2 rings, but one of them is on the inside of the concave surface of the helmet.
Its impossible to get a bead on this stuff, I swear.
That said, I'm sticking with my "one ring of color" plan - the electronics are already taxing battery life, I'd rather not push it if I can afford to. Plus, there's so many variations - who's to say this isn't actually one of them?
This weekend, I messed around with some polyester resin and fiberglass cloth casting. I've had issues with chroming urethane before, as the baking/curing process can sometimes deform the pieces. The shop I've worked with has since figured out a way to rectify this for urethane helmets, but I felt that a little proactive measures on my part wouldn't be a bad idea.
Polyester resin and cloth will also make my cast piece very, very thin by comparison, and that gives me more wiggle room for mounting the LED matrix. I did some test fits in my mockup urethane casting, and the amount of material I'd need to remove from the visor area was making me slightly uneasy.
Here's a shot from the inside while the resin was curing:
The "X" marks are indicators where I've laid down a second piece of fiberglass cloth. This way I can make sure I don't skip any spots.
Finished results were pretty good for my first crack at this. A few areas where I missed layering, but these are smallish bubbles and can be taken care of with more resin or bondo after I've done some trimming.
I also made a set of ear pucks from polyester resin, and embedded a blind nut into the part. These will hold the outer ear against the clear disc and the circuitboard in place.
Things are picking up speed now, hoping to have the buckets ready for chrome by the end of the week.
KaanE
Sr Member
Re: Daft Punk Thomas Bangalter helmet build
It looks awesome Volpin, I love fiberglass so much, a lot more than resin. It's harder to work with but the end result is far better IMO. What I would have made is add a GelCoat "coat" before the fiberglass, this will give you an easy to work surface.
I can't wait to they day it has all the leds lighting up correctly!
It looks awesome Volpin, I love fiberglass so much, a lot more than resin. It's harder to work with but the end result is far better IMO. What I would have made is add a GelCoat "coat" before the fiberglass, this will give you an easy to work surface.
I can't wait to they day it has all the leds lighting up correctly!
Re: Daft Punk Thomas Bangalter helmet build
One of these was done with cabosil and the other just straight resin. I need to see if I can find some proper gelcoat for the future, but these were still pretty successful in the end. Happen to have any supplier links?
One of these was done with cabosil and the other just straight resin. I need to see if I can find some proper gelcoat for the future, but these were still pretty successful in the end. Happen to have any supplier links?
KaanE
Sr Member
Re: Daft Punk Thomas Bangalter helmet build
I do not live in the USA and I can't understand why smooth on doesn't sell any but what you could do is using urethane resin as a Gelcoat and then do a fiberglass backing with polyster resin.
I do not live in the USA and I can't understand why smooth on doesn't sell any but what you could do is using urethane resin as a Gelcoat and then do a fiberglass backing with polyster resin.
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Agent RayBans
Sr Member
Re: Daft Punk Thomas Bangalter helmet build
Nice find! I'm not sure if its cool or depressing that we're still figuring out little details about these helmets.
The fiberglass helmet looks great! Man, what I'd do to get one of those...
Nice find! I'm not sure if its cool or depressing that we're still figuring out little details about these helmets.
The fiberglass helmet looks great! Man, what I'd do to get one of those...
ThreeFN
Member
Re: Daft Punk Thomas Bangalter helmet build
Actually, about 25% to 33% of what I do for a living is working with glass fiber and composites. Here's a handful of tips if you're interest.
1) I personally hate polyester resin. It's foul smelling, it burns, and it makes you angry I much prefer epoxy resin. specifically, West Systems epoxy is the stuff I have the best track record with. As long as you take reasonable precautions you won't have any trouble with cumulative epoxy allergies.
2) Gel coat is typically useful. As far as I remember it helps the de-molding process and is an easy way to add even color (ie paint) to a part.
3) Sharp edges and corners are very prone to damage and chipping because it's very difficult to get the cloth into the tight corners to reinforce the resin. To fix this, use glass fiber 'tows' stuffed into the corners and edges before you add the cloth. Glass tow is an unwoven 'thread' of continuous glass fiber, typically comes on spools. This technique will get more material into that corner/edge and make it stronger and more robust.
Actually, about 25% to 33% of what I do for a living is working with glass fiber and composites. Here's a handful of tips if you're interest.
1) I personally hate polyester resin. It's foul smelling, it burns, and it makes you angry
I much prefer epoxy resin. specifically, West Systems epoxy is the stuff I have the best track record with. As long as you take reasonable precautions you won't have any trouble with cumulative epoxy allergies.2) Gel coat is typically useful. As far as I remember it helps the de-molding process and is an easy way to add even color (ie paint) to a part.
3) Sharp edges and corners are very prone to damage and chipping because it's very difficult to get the cloth into the tight corners to reinforce the resin. To fix this, use glass fiber 'tows' stuffed into the corners and edges before you add the cloth. Glass tow is an unwoven 'thread' of continuous glass fiber, typically comes on spools. This technique will get more material into that corner/edge and make it stronger and more robust.
Re: Daft Punk Thomas Bangalter helmet build
Thanks for the tips, 3FN. Ever worked with milled glass fiber before? I'm thinking that may be something to try on my next attempt - the small strand bits may make things easier in terms of getting small details to take fiber and be more than pockets of resin.
Thanks for the tips, 3FN. Ever worked with milled glass fiber before? I'm thinking that may be something to try on my next attempt - the small strand bits may make things easier in terms of getting small details to take fiber and be more than pockets of resin.
ThreeFN
Member
Re: Daft Punk Thomas Bangalter helmet build
Haven't technically had much experience with milled fiber, though from what I understands it's not much different from chopped fiber, except that it's typically hammered rather than cut so it's finer and 'softer' in it's consistency.
Should work fine for your application, probably better/easier than tow since it's more 'amorphous.' Sometimes I need to remind myself that not every application needs to be engineered for strength/stiffness and impact resistance (heavy weight RC plane landing gear, for instance). Years of college making excessively precise fiberglass competition wings will do that to a man:rolleyes
Have you any thoughts on vacuum bagging? It's a bit of overkill but it's a great way to remove bubbles and improve consistency.
Haven't technically had much experience with milled fiber, though from what I understands it's not much different from chopped fiber, except that it's typically hammered rather than cut so it's finer and 'softer' in it's consistency.
Should work fine for your application, probably better/easier than tow since it's more 'amorphous.' Sometimes I need to remind myself that not every application needs to be engineered for strength/stiffness and impact resistance (heavy weight RC plane landing gear, for instance). Years of college making excessively precise fiberglass competition wings will do that to a man:rolleyes
Have you any thoughts on vacuum bagging? It's a bit of overkill but it's a great way to remove bubbles and improve consistency.
Re: Daft Punk Thomas Bangalter helmet build
Unfortunately, the mold wasn't really made for vac bagging. I had considerations about it, but I'm thinking that the air in the silicone could deform the pull, and the edges of the mother mold are also too sharp to work with a vac bag.
The brush method should do fine, even the casts I have now are alright, the bubbles are pretty minimal and easy to clean up.
Unfortunately, the mold wasn't really made for vac bagging. I had considerations about it, but I'm thinking that the air in the silicone could deform the pull, and the edges of the mother mold are also too sharp to work with a vac bag.
The brush method should do fine, even the casts I have now are alright, the bubbles are pretty minimal and easy to clean up.
ThreeFN
Member
Re: Daft Punk Thomas Bangalter helmet build
I'll be the first to admit vac bagging has a very narrow set of uses when you get the most out of it. The rest of the time it's just a tricky bugger.
I'll be the first to admit vac bagging has a very narrow set of uses when you get the most out of it. The rest of the time it's just a tricky bugger.
Re: Daft Punk Thomas Bangalter helmet build
I had a ridiculous idea a bit ago to slush cast one using ridiculously gaudy black glitter as filler. Maybe one day when Ive had a few drinks.
Started sanding/cutting the helmets today. Both are coming along well, will probably have them ready for chrome by next weekend!
Oddly, that little cheek bubble present in all my slushcasts didn't come through in the polyester resin casts. Couldn't tell you why...
I think you should make a carbon fiber one next, sell it to me, and ill finish it in pure, beautiful, carbon
I had a ridiculous idea a bit ago to slush cast one using ridiculously gaudy black glitter as filler. Maybe one day when Ive had a few drinks.
Started sanding/cutting the helmets today. Both are coming along well, will probably have them ready for chrome by next weekend!
Oddly, that little cheek bubble present in all my slushcasts didn't come through in the polyester resin casts. Couldn't tell you why...
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