Guy-Man Costume Build

[Zorlord]

Hey guys,

Ive decide to start working on a Guy-Man Helmet/ Costume for Halloween.. Unfortunately i won't be the one wearing it, as my girlfriend has expressed interest in wearing it.

This is my second project, my first being a Deadmau5 head

Onto guy-man!

I started with a Pep Base:

fiberglased the inside, resin'd the outside

got sick of the visor, and thought it would make it easier to handle/work with if i cut it out, so i did

glued card "guides" i guess you call them to help me achieve a cleaner edge.. I may need to find another material to work with to attempt to get better edges.. if anyone has any suggestions please post..

currently sanding everything by hand.. it's super tedious and very slow, so im debating about buying a small sander to make it easier..

So far problems i've been encountering:
Bondo having gaps and surface blemishes that i cannot seem to fill in
Achieving a clean, sharp edge on my edges, as well as the edges that would secure the visor. I've been looking at milliput, or maybe some air-drying clay to achieve a better edge, but i'm not sure if these materials will work..

Thanks for looking, and any help is greatly appreciated.

 

[scottcoates]

how did you do your Deadmau5 helmet ? it looks really good

 

[Zorlord]

how did you do your Deadmau5 helmet ? it looks really good

Very carefully haha.

Search on the forum for "deadmau5" and theres a 100+ page thread on it.. Just took that information and did it myself.

 

[firebapx]

im currently making one of these the excate same way you are with the pep files any thoughts on how your going to do the visor ?

 

[justanuthercap]

Believe it or not Bondo will work for sharp edges. Just use a razor blade or xacto to cut it the way you'd like right after it starts to harden. It's a "rubbery gel" stage before it hardens that is when you want to cut it.

 

[Zorlord]

im currently making one of these the excate same way you are with the pep files any thoughts on how your going to do the visor ?

I cut the visor out so i could get cleaner edges for where the visor meets the mask. I think im going to try to get some clear plastic and heat it up and bend it to the correct shape.. Not to concerned about that at the moment though

Believe it or not Bondo will work for sharp edges. Just use a razor blade or xacto to cut it the way you'd like right after it starts to harden. It's a "rubbery gel" stage before it hardens that is when you want to cut it.

Okay, ill have to try to do that. Thanks

 

[Zorlord]

updates:

I know its not 100% correct, but im in a time crunch for halloween.

 

[Zorlord]

some updates.

 

[Crank729]

Looking good!

 

[Zorlord]

Looking good!

haha "good" is an overstatement.. Compared to some of the helmets out there this looks alright... But i suppose for a first time it isnt that terrible. Does anyone have suggestions for the thickness of the PETG sheet for the visor? Also, is it possible to mold the visor without a vac table?

EDIT: Looked through old PM's and found a that crank used 1/16th PET or PETG plastic.. Looks like thats what ill be going with then.

 

[Zorlord]

More updates!

Since these pictures have been taken, the gaps between the visor and body have been filled. Im content with the helmet's body (for now, need this done by halloween) and now im just working on smoothing out the visor for vacuum-forming.

I bought two sheets of PETG plastic for 22 bucks shipped to my door (2ft x2ft x 1/16th inch)

 

[Zorlord]

Im back from the dead. Didn't meet my halloween deadline, so i rage-quitted and hid my helmet in the garage for 6 months.

I decided to re-make the visor, because the one that i have is terrible and dumb and i'm sick of it, So i made another one out of paper, and plan to mache it into the correct shape (or more correct shape, it's still a bit wonky), then hopefully vacuum-form off of that.

If anyone is interested and researching how to make a vac-table, I can take pictures of my vac table and explain how I made it and such :lol