Major Grubert
Member
Thor God of Thunder (current comics) Helmet build for cosplay at Anime Expo 2015.
Overall pretty good, though I ran into the typical time crunch at the end which led to cutting corners in the paint area. First time making a helmet, foam part was relatively easy though I would go will a brand name contact cement rather than the VOC free stuff I bought (at Home Depot)
Materials
-EVA foam
-1/8th inch Sintra sheets
-Bondo
-Contact cement and Loctite gel control super glue
-Rustoleum 2X primer and Metallic Chrome
Tools
-Blades of Exact Zero (Xacto)
-Dremel (grinding)
-Bondo spatula
Nephew (cosplaying Odinson) fooling around with the helmet.
View attachment 498195
'Wings' - I did the wings first. The shape is a bit complex so I made a mold out of SmoothOn Air Epoxy in the shape, heated the Sintra template and then pressed it onto the mold with EVA molded to the mold. I did this so I could press evenly. I cut out the center oval for a better press shape, and then cut and new one and pressed it through the hole. Added Xacto cuts to simulate tooling.
View attachment 498197View attachment 498198View attachment 498199
I found a helmet tutorial and made a very basic helmet out of EVA. To get the conical shape I made a cone out of construction paper and glued it to the top of the helmet and then started layering in Bondo, with general 150 grit sanding in the between. I then cut shaped the face area with a mannequin head and cut out the eyes.
From there I made the 'ram horn' shape that is on the front of the helmet out of 1/8th Sintra and feathered/sanded Bondo for shape. Before I glued the 'ram horn' symbol I sanded and polished (1500 grit) the bondo underneath.
I really needed two more days of sanding prior to painting but I was out of time.
View attachment 498222View attachment 498223
Again, came out fine for the 'six feet' from the camera cosplay pics. Will post the rest of the Thor props, and Lady Sif's props in separate threads.
- - - Updated - - -
Sorry, pics that are missing from above. . .
Overall pretty good, though I ran into the typical time crunch at the end which led to cutting corners in the paint area. First time making a helmet, foam part was relatively easy though I would go will a brand name contact cement rather than the VOC free stuff I bought (at Home Depot)
Materials
-EVA foam
-1/8th inch Sintra sheets
-Bondo
-Contact cement and Loctite gel control super glue
-Rustoleum 2X primer and Metallic Chrome
Tools
-Blades of Exact Zero (Xacto)
-Dremel (grinding)
-Bondo spatula
Nephew (cosplaying Odinson) fooling around with the helmet.
View attachment 498195
'Wings' - I did the wings first. The shape is a bit complex so I made a mold out of SmoothOn Air Epoxy in the shape, heated the Sintra template and then pressed it onto the mold with EVA molded to the mold. I did this so I could press evenly. I cut out the center oval for a better press shape, and then cut and new one and pressed it through the hole. Added Xacto cuts to simulate tooling.
View attachment 498197View attachment 498198View attachment 498199
I found a helmet tutorial and made a very basic helmet out of EVA. To get the conical shape I made a cone out of construction paper and glued it to the top of the helmet and then started layering in Bondo, with general 150 grit sanding in the between. I then cut shaped the face area with a mannequin head and cut out the eyes.
From there I made the 'ram horn' shape that is on the front of the helmet out of 1/8th Sintra and feathered/sanded Bondo for shape. Before I glued the 'ram horn' symbol I sanded and polished (1500 grit) the bondo underneath.
I really needed two more days of sanding prior to painting but I was out of time.
View attachment 498222View attachment 498223
Again, came out fine for the 'six feet' from the camera cosplay pics. Will post the rest of the Thor props, and Lady Sif's props in separate threads.
- - - Updated - - -
Sorry, pics that are missing from above. . .