rocketeer helmet

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glyntheelf

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

the helmets being 3d printed
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after a very long time ive finely got it all taped together to make sure it all fits nice.
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i then slush cast the inside with fast cast resin.
20150815_150542.jpg

the fast cast fills in any gaps and holes saving a bit of work filling with epoxy resin.
IMG-20150812-WA0000.jpeg

i then started to sand it with 60 grit sandpaper, thats should give it a good bed for the filler primer to bite onto.
20150815_150454.jpg

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.
 

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Ein

Sr Member
RPF PREMIUM MEMBER
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?
 

glyntheelf

Jr Member
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.
 
Last edited by a moderator:

glyntheelf

Jr Member
i chopped the fin off today and finished sanding
20150816_130513.jpg

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.
20150816_130533.jpg

iv now can use the fin as a template to make it one piece.
20150816_130608.jpg

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.
20150816_131002.jpg20150816_131008.jpg
 

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glyntheelf

Jr Member
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.
20150818_111321.jpg

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
20150818_185804.jpg

i also made a start on the fin, i traced round the original onto a 5mm polycarbonate sheet
20150818_185647.jpg
still needs sanding and shaping but it will be perfect for what i need.
 

glyntheelf

Jr Member
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.
 

glyntheelf

Jr Member
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
20150819_170800.jpg
then sanded off with the gaps gone
20150819_173716.jpg
 

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glyntheelf

Jr Member
ive been doing some work on the glove controls for the past week
20150831_214127.jpg20150831_214144.jpg20150831_214220.jpg20150831_214229.jpg

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
20150828_165318.jpg
 

glyntheelf

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

20150914_133123.jpg20150928_202500.jpg20150925_122804.jpg20150928_202512.jpg20151127_163057.jpg

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

1444329370350.jpg

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

20160320_123015.jpg

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.

20160320_122748.jpg20160320_122726.jpg

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

20160320_122822.jpg

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,

20160307_181129.jpg

ive also orderd some gaiters to go with some boot.

this is the jacket i ordered

http://www.ebay.co.uk/itm/Custom-Tailor-Made-All-Sizes-Genuine-Leather-Jacket-ROCKETEER-5th-YEAR-EBAY-SELL-/231343460140?hash=item35dd250f2c:g:HuQAAOSwPe1UJALn

and the breeches

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

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