So I fibreglassed the helmet model. This basically involves making your paper model out of 250gsm paper, taking a lot of time and glue (I use PVA) to ensure everything is exactly where you want it. Following that you resin the outside of your model. Do this once or twice, the more layers the tougher the base to work with. For this one I did a layer on the outside and one on the inside at the same time, which was tricky (soggy paper!).
Once that was completely dry I applied a thin layer of resin to the inside to form a sticky surface, then fibreglass sheets and more resin to strengthen.
After the fibreglass was dry I cleaned it up a little with the rotary tool (since dry fibreglass matting can cut and stab like crazy). I applied a layer of filler to one section of the outside, allowed it to dry then began sanding. If there are uneven areas it doesn't matter as they'll get fixed up a bit later.
It was then that I realized that in my haste to get the project done I had forgotten to sand the outside to roughen up the helmet. This allows the filler to adhere a bit better. So I sanded the rest of the helmet with 80 grit just enough so it lost the resin shine. Time would tell if the initial layer of filler would stick. But so far so good!
I did a test fit and my god I'm glad my head is bigger than most as putting it on was fine but taking it off... I was worried it was stuck! The size should be good for the owner as it will give him some breathing room (the helmet has no vents according to all the reference images
Which brings us to current status! I have applied some more filler across the right hand side of the helmet, along the top and in patches on the initial area (to fill shallow parts). Once this is dry I will sand back, reapply filler and move on to other areas.
So that's it for now, the next update will mostly be more sanding! Though I may look at some detail work while I'm at it (such as the bolts at the back of the helmet etc). Adios!
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