Halo Reach Commando (Carter) Helmet

I started this project a few years ago with a 3D model, and finally have started bringing it to life. Since March I've sent the model off for printing and have begun adding more details and molding. Due to the crazy weather we've been having in Texas, curing conditions, drying times, and anything else that mother nature could throw at me to damper my schedule, its happened. But, turning my guest bedroom and tub into a new work area, work must continue. I think another good sanding and wax, and we'll be molding in no time! Thanks for stopping by!



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Time for a BIG update.
After a long week and many hours of sanding, I'm finally starting to see the finish line. In the picture you will see the big difference that wetsanding makes. Yea it takes longer to do and yea it's going to be painted over so who cares...I CARE, it looks Badass! I plan on my molds lasting a long time and being able to produce the cleanest casts possible. The top half has only had a quick pass with 1000 grit and the bottom is untouched. The whole helmet will have two full passes and waxed before molding. And speaking of, Silicone WILL be laid tomorrow afternoon! So stay tuned for more updates!


Oh the joys of filling! Thank god for spot putty, now there are no more pinholes!
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Amazing skills, i was working on same helmet some time ago but had some bad luck plus bad weather and now i don't have helmet anymore :( anyway that is some badass skills you have great work!
 
And an even bigger update!

After months of trial and error, its finally molded, and my first successful cast of the rubber neck. Finally after months of researching how to cast with rubber, many failed attempts, gallons of wasted rubber, it finally worked! Anyone need to buy a full gallon kit of Brush On 35!? Never been touched except for 1 test.

















 
I would love to know more about the process of molding the rubber in. If you don't mind sharing at least that is.
 
The rubber neck seal is an awesome idea! I guess that is Polyurethane rubber? Very Nice! Are you going to incorporate this into the Master Chief helmet as well?
 
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