Resin and Bondo Questions for a Newbie?

strifestreak

New Member
Hi guys, I'm very new here so first I apologize if this is in the wrong section.

I just started work on a very big project (Subject Delta) and while most everything is under control I am having a hell of a time deciphering bondo and fiberglass resin.

We started work on the helmet, and using Volpin's tutorial (of course) we first sculpted it out of expanding foam. I considered pulling it out of resin but it's way too huge for that so we opted for this method instead.

My biggest concerns right now are;
A) Some of the bigger holes left by the foam
B) Coating the foam to protect it
C) How easily can you drill/cut through resin and what should I use to do so?

After shaving the expanding foam we were left with a swiss cheese-like piece (which was expected) but a few holes are rather big and I started to think we might have to cover them up. I was thinking about using bondo to cover the holes but I wasn't sure if it would damage the foam, and on top of it I wasn't even entirely sure if the bondo would be too heavy in the end because the helmet was going to be worn as is, not casted in resin. I also thought about maybe using Apoxy Sculpt but I wasn't entirely sure on that either.

Next, I know everyone's going to opt for ureshell but I haven't been able to find it cheap and we've already spent $150+ so I'd rather not spend another $80 on ureshell. If you guys could direct me to someplace where I can get it cheap or a good alternative I would very much appreciate it.

Lastly, for the tanks on the back I was thinking about just bolting them on with screws (in order for them to be fully secure) to the back piece of the helmet but I was rather concerned about how fragile resin is or how hard it is to drill/cut through since I have never worked with the stuff prior to this.

Thank you very much guys for any and all help I appreciate it :)
P.S. Any tutorial links to working with bondo or resin would be truly appreciated!

Here is a reference to the costume

subject-delta-674x461.jpg
 
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