rocketeer helmet

so ive started work on a Rocketeer costume. starting with the helmet.

the helmets being 3d printed


after a very long time ive finely got it all taped together to make sure it all fits nice.


i then slush cast the inside with fast cast resin.


the fast cast fills in any gaps and holes saving a bit of work filling with epoxy resin.

i then started to sand it with 60 grit sandpaper, thats should give it a good bed for the filler primer to bite onto.


and that's where im at so far, i plan on chopping off the fin so i can make a single part as its not that strong as it is. i also plan on making it out of polyurethane in the end. hope you finheads like it and if you guys have a any tips and tricks please let me know.

next up will be the glove flight controls.

 

That's quite clever! I like it. Never thought to slush cast a 3d print like that just to hold it together. It looks like you didn't get too much leakage, too.

The fin being a single piece is definitely the right idea.

Did you make the files you printed?

 

thanks Ein, no i didn't make the file i had to edit it a little to be able to print it and re-size it. i believe it was this file by davypenno2
http://www.thingiverse.com/thing:850699
slush casting works a treat. best to sand the insides to help it bite but other then that its great.

 

i chopped the fin off today and finished sanding


i cut just below the 3d printed plastic leaving the resin in tacked, that way it keeps it strong then filled in the gap with car filler.


iv now can use the fin as a template to make it one piece.


when i come to fixing the fin to the helmet i will wax the fin first then add the weld lines to the helmet and fin. this way i will be able to remove the fin so it makes it easyer to cast.

ive also made a slow start on the gloves. still need to cut them down.

 

took all day but my gloves are cut and stitched read for dyeing and the rest of the leather to be added.

 

Subbed...that helmet sure looks great. Eager to see the rest

 

today i finally got to give it a few coats of filler primer. the first coat its just a thin coat. this raises the plastic fibers so that i can sand them off with 120 grit paper as you can see in the first pic. the dark patches are where the fibers are standing up.


i then gave it i good few coats to help fill in the gaps i then sanded the gaps back to the plastic leaving only the primer in the grooves. then another good coat


i also made a start on the fin, i traced round the original onto a 5mm polycarbonate sheet

still needs sanding and shaping but it will be perfect for what i need.

 

why not make the fin out of aluminum?

 

Good idea JPH I just had the polycarbonate knocking around. But I might have a look to see if I have any aluminium. Would definitely be better.

 

today i used some cellulose stopper to fill in some big lines and pin holes, if you have never used this stuff its great it like a very thick paint that can be sanded withing minutes and isn't as hard to sand as body filler.

stopper applied

then sanded off with the gaps gone

 

Looking spiffy:cool

 

ive been doing some work on the glove controls for the past week


ive also made a rocket base/booster using a lathe and some high density foam. i will make a mold and make two hollow casts of this

 

ive done a bit more work on the helmet, almost time to add the weld lines and cast.

 

hay guys its been a while since i last posted but i have been working on my project. i cast my rocket boosters



i also had to make a silicon *coff* plug for the inside of the boosters



as for the fuel pipes i got some flexable water pipes and screwed some bolts into the end then cut the heads off and screwed then into some pre drilled holes on the booster



the gray pipe i will be using is 6" soil or drainage pipe.

the gloves are almost fully complete now, i want to add some straps up the arms to keep the cables in place if i dont have a jacket on but that will be a small addition.



to connect the buttons to the jetpack i have some 3 pin connectors



these will be great so i dont have to struggle getting out the pack and gloves at the same time.

ive also bought most the costume now,



ive also orderd some gaiters to go with some boot.

this is the jacket i ordered

http://www.ebay.co.uk/itm/Custom-Ta...460140?hash=item35dd250f2c:g:HuQAAOSwPe1UJALn

and the breeches

http://www.ebay.co.uk/itm/111848930239?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT

 

bother boosters are finished and painted.