WerewolfCop
New Member
Been a long time reader of these forums but finally decided to join. Before I start I'd just like to tip my hat to you guys and say thanks for posting all your awesome work. Really inspired me and taught me a lot. Right now I'm building the MK6 helmet, I've made 2 foam and halfway through a card stock one from peping. I'm really liking the Foam route. And as I make more I'm learning little things here and there that are improving my skill. What does concern me is the rigidity of the foam and trying to connect the servos to the faceplate. I'm using 5mm craft foam from Hobby Lobby (Silly Winks) and the stuff is great to work with. I spent this weekend experimenting with applying fiberglass resin and cloth to this foam and found that after giving the foam a light sanding the resin adheres to the foam just fine with very little warping if you brace it. But I don't want to go the fiberglass/bondo route which I think defeats the purpose of a foam build (opinion). So I have an idea to engineer a way to give the helmet some strength to hold the servos to open and close the faceplate and was curious if anyone has tried this and has any feedback. I was watching Stealth's tutorial on forming plastic for the eye's when I thought of this. I'm thinking about taking a flat piece of plastic sheet, cutting it to the shape of the back of the helmet and using my heat gun to form it to the inside of the helmet. Not talking about melting the plastic but heating it just enough to change it's shape. I'll do the same to for the faceplate. If the shape of the plastic conforms to the shape of the inside of the helmet it will give it strength on the sides and top of the inside of the helmet. I can then attach my mounts to the plastic and line it up to the plastic on the faceplate. Once everything is in line I can glue the plastic onto the inside of the helmet and it should work (In theory). Anyone tried this? I'll have some video of my progress soon, for some reason it's not uploading right now.
