Here is a pic of the depth so far...keep in mind...I am a long way from done:
Once the bondo cures (48 hours to be sure)...I sanded it smooth and applied the light coat of primer as a "base" to start my working on the lines and depth.
For the mask, I dremeled out the area between the front plate and the rear plate, all the way through. I then added Milliput behind the "gap". I don;t really like the cure of the Milliput, so I am removing it and replacing it with "Steel Stick" a harder cure. But, after the MP "cured" I did this:
This gave me the "space" between the two plates. I also removed some of the thickness of the "nose piece" (between the chrome inlay and the back plate) and then molded some Steel stick into the area (use a toothpick to have something to build to), to fill the gap. I will be doing a lot of clean up work and shaping with a thin coat of bondo (so I can sand smooth and shape after cure) to the nose area.
For the helmet lines, I essentially did the same thing with the dremel (using the steel wheel brush), like this:
I used a Needle file like a pen, and "drew" my depth lines in the bondo, this took quite some time. I then used a round needle file, and (very slowly and carefully) filed a small "channel" in the bondo where I wanted the lines to go. After they were slightly there, I turned the dremel wheel at a 90 degree angle, and I brushed the side closest to the "eye"...or the outside of the helmet, like this:
What that does is build the inside up, to give it more of a pronounced look. This is for the lines running down the length of the helmet, and the ones coming down the sides from the indentation already in the helmet, as well as the "cheek flares" with the wheel to the front of the helmet. I just made an even pass around the rear.
What helped, I think, was the layer of resin and bondo. Once my wheel touched the black plastic...my depth was really defined. Another good thing about the steel wheel brush on the dremel, is it tends to smooth out the plastic, which is hard to get a good sanding.
the biggest thing for me, is to go slow and steady, I have no need to rush as my "Soft Parts" for this costume are going to take a while to fabricate / sew, etc.
So far, I really think I am getting good, clean lines, good depth on the faceplates, and it'll be a good look when I do the final texture and paint.
I'll post my progress and the final product when I am done. I know there are a lot of BS Mods...I thought maybe there were some folks who simply didn't want to do the Disney weld and fitting. So I thought I would share my "option" to make a nice, solid KR helmet with the right look and detail.
More to come!
Jon