Dead Space - My first costume and prop attempt

Today is the only day that I got to, or will get to play in the shop this weekend. I had made up my mind that I was going to follow Captain Hask's instructables and sculpt the helmet. I figured while I waited for those supplies to arrive in the mail I would see if I could make one out of foam to pass the time. You know, just for s***s and giggles. It started off super rough. I didnt consider the thickness of the foam and it was too tight on my head. So I cut the middle seam and added a half inch piece so it would fit. After all, this was just to pass the time.



I started having fun with it. Adding a little here, a little there.





I took thin diamond back foam to make the foundation for the rest of the face shield to stick to.



Once it was done, I bent the crud out of it and taped the curve in place. While bent, I blasted it with the heat gun and let it set for a couple of hours.
After it set there hopefully holding its shape, I glued 2 strips of styrene to the back of each side where the face shield would adhere to the helmet. It made it a little more rigid and sturdy. After little bits and detail pieces were added, it didn't look too bad.



So, I have a huge favor to ask. I want to see how smooth I can get this. If I coat this in enough coats of Epsilon, can I sand that down well enough so that you can't see the seams where I glued the helm together? I have never used Epsilon, but I have seen from Bill Doran's videos that it makes a pretty rigid shell on the exterior. If Epsilon is a poor choice, what would you recommend I coat this in so I could sand the gaps out?
 
DUDE!! if that's for S.A.G'S I cant wait to see what's next!!!! oh what the hell....BAD ASS!! :$ sorry mod's... had to say it. :angel I have no idea what Epsilon is....im a die hard bondo guy myself...;)
 
You've got a nice tag team partner of a wife! Helmet and top lookin' amazing! Not sure what Epsilon is though. :( Hope someone with experience can help you out!
 
She is a pretty cool chick. ;)

Epsilon is an epoxy coating for foam made by Smooth-on http://www.smooth-on.com/Epoxy-Coatings-EPS/c1397_1400/index.html
Its more expensive than I thought it would be so I passed on that idea. The shipping was almost as expensive as the trial size container.

I used Mod Podge instead. Its still far from perfect, but 4 or 5 coats of mod podge and sanding did help. After sanding, the helmet got multiple coats of plastidip, primer, and now for paint. 1st coat down!

 
So, I found these tea lights on ebay that are the perfect color. I bought a hand full of them, de-soldered them from their board and stuck 'em through a thin strip of foam. A little solder, a lot of hot glue, they ain't breaking on me! While the helmet cures tonight i will make 3 of these strips and stick them in tomorrow along with some semi-frosted plastic to diffuse the light.






 
cant wait to see this helmet done!. are you using one battery source for all the strips? or are they each on a 9v?? :thumbsup
 
SWEEEEET! tears of joy bro!! congrats :cool can you "kinda" see thru the plastic?

Thanks! Nope, can't see through the plastic at all. I left a small slit between the plastic and the foam in the middle section. It's a thin slit that allows some visibility. It's not great but not horrible.
 
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