So far I'm primarily working on the helmet. I decompiled the in-game model and edited it to make it more suitable for making and wearing, then made a pep file from that. I put together the pep, resined it, glassed it, put rondo on the inside and smoothed out the outside with bondo (and ended up doing quite a bit of reshaping in certain areas as well).
Here's where I am right now, the thing is basically done and primed, ready to be painted and have additional parts added (filters on the front and other greeblies on the back of the head).
Here's the in-game model: http://i.imgur.com/oIRTkec.jpg
Some people expressed an interest in copies of the helmet. I'm considering it, but I want to know if it's safe for the master copy to create a mold if it's already fully painted. From what I've seen, molds are usually made from clay sculptures, or pepped objects that are only primed--not painted. Basically I want to continue working on what I have so far and read up on molding and casting in the meantime, but if making a mold could risk damaging the original or its paintjob in some way, I'd want to make the mold and casts first.
To sum up: is there any possibility of harming the (fully painted) master copy in the process of making a mold?
Thanks for reading! You are all an inspiration!
Here's where I am right now, the thing is basically done and primed, ready to be painted and have additional parts added (filters on the front and other greeblies on the back of the head).

Here's the in-game model: http://i.imgur.com/oIRTkec.jpg
Some people expressed an interest in copies of the helmet. I'm considering it, but I want to know if it's safe for the master copy to create a mold if it's already fully painted. From what I've seen, molds are usually made from clay sculptures, or pepped objects that are only primed--not painted. Basically I want to continue working on what I have so far and read up on molding and casting in the meantime, but if making a mold could risk damaging the original or its paintjob in some way, I'd want to make the mold and casts first.
To sum up: is there any possibility of harming the (fully painted) master copy in the process of making a mold?
Thanks for reading! You are all an inspiration!