This project has been a long time coming. I've loved the look of this character since I was a kid watching the show. I originally set out to make it when I first joined the RPF. Then, after researching, I realized just how far beyond my skills it would be to create a costume of which I would be proud. So it got pushed to the back burner. Now I'm tackling it.
I'm starting from the top: the helmet. First and foremost, I owe a debt of gratitude to @laellee for the 3D model of the helmet, not to mention the invaluable advice he has provided on how to tackle each individual aspect. Here is the render:
It is actually 5 separate pieces. The body of the helmet, a visor buck (from which I will vacuum form a tinted visor), the "iris," the "pupil" and a backer plate unseen in the render which will live behind the "pupil" and act as housing for the LED that will illuminate in blue.
The pieces have slowly been 3D printed as time and money have allowed, but I finally have some progress to show on the helmet construction. I had it printed via Shapeways (expensive... but I think it was worth it). I sanded down the raw print with 150 grit, then it was time to tape it up and hit it with the primer.
I went through 4 coats of primer, wet sanding between each one with gradually finer grits, as necessary (320 to 600 to 1000). I alternated between gray and white, so that I would know how far I was sanding through the freshest layer.
Currently, it has received two coats of white. All that is left to do is seal it with a crystal clear enamel.
The visor buck is being printed by Shapeways right now. I also ordered the pupil from them in their Frosted material, so as to diffuse the blue LED (also in transit to my location). More progress to be posted as it is made!