RogueTrooper - The bodyfiller was "uncooperative" . Joking aside I bought a mouse sander during making this and that was a godsend. It was also the first time I have used spot filler, really helped sharpen the lines.
MaarekSteele - Extra Height? Do you mean the raised edge with foam tape (third image from top left) I used those squares (which were just foam tape) as height markers while applying the bondo. This was one of my many mistakes and removed them for further bondo applications
It seems like a few forum members that have tried this, but got sick of the sanding, sanding and more sanding (did I mention the sanding?).
I started this around xmas and left it alone for months because I was sick of looking at it. I remember times when the paper model would show through the bondo and the more you sanded it down the rougher it got. I had to grind out the offending area with a dremel and refill it with auto filler.
Then there was time I masked off and spray painted the red "band". It went on perfectly - sharp lines, no overspray. Then I went over it with clear coat and the surface went all "crackly". I think I was painting when it was too cold. I was so angry I nearly smashed the helmet.
I totally understand the sentiments of the above comments.Before this I had done a few foam pepakura helmets (Batman, Captain America) and I can see why its become popular. A LOT faster and easier than the cardboard/bondo method