I'm almost done with this project but I thought it was close enough to show. Although not the fanciest, there was always something that I liked about the Stark helmets.

I started by sculpting the helmet in 3D during lunch and then running it through Pepakura to make the paper model.

I slushed some Smooth-On Onyx resin (because I had a lot of it) inside to build up a thick wall.

A ton of sanding and Bondo later completed the basic shape. The crest was added with Bondo instead of trying to get that detail into the paper model.

To make the rolled edge, I cut a template out of plastic and squeegee'd Bondo around the rim.

This was sanded smooth and then notched with a Dremel cutting wheel.

After making a mold, I was able to cold cast a copy using aluminum powder. It adds some nice weight to it and gives a great metal sheen.

I still have to pad the interior but the hard part is done!



I started by sculpting the helmet in 3D during lunch and then running it through Pepakura to make the paper model.

I slushed some Smooth-On Onyx resin (because I had a lot of it) inside to build up a thick wall.

A ton of sanding and Bondo later completed the basic shape. The crest was added with Bondo instead of trying to get that detail into the paper model.

To make the rolled edge, I cut a template out of plastic and squeegee'd Bondo around the rim.

This was sanded smooth and then notched with a Dremel cutting wheel.

After making a mold, I was able to cold cast a copy using aluminum powder. It adds some nice weight to it and gives a great metal sheen.

I still have to pad the interior but the hard part is done!

