Now that my armor is done, I have used halloween as an excuse to make luke his. He picked a mandalorian armor as his kit. So i got started.

Been working on the helmet for the last month or so. Started using a pepakura file. I used cardstock as my medium, cut it and glued it together.

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After I got it where i wanted it, I put resin on the outside and fiberglassed the inside.

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Once that dried, I bondo'd the outside and sanded it smooth.

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once that was done, I put a coat of primer on it just to make it look better

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Then it was time to make the mold. I went the cheaper route and just used silicone from Home depot.

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Then it was time for the mother shell. Made from fiber glass.

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when the mothershell dried, it was time to remove the pep helmet

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Then I started slush casting helmets from it.

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so now i get to do some sanding, painting and such. can't wait.

here's the Orioles themed paint scheme we are going with.

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Use the force, Luke
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Vary cool
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that's so cool, it's looking great :-)
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Very cool!
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thanks

did some sanding clean up last night and cut out the t-visor area. got luke to do a little modeling.

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went to home depot today and got the paint. going to do an under layer of hammered silver and use the vaseline technique so that you see the metal look under the battle damaged areas of the armor.

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Little short for a stormtrooper isn't he? :-)
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Holy snikes, count me impressed! Fine job, sir!
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started painting today. first was the primer and then the hammered silver paint.

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Cool!!
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Will you be my Dad?Image
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well. after having a heck of time with the first can of orange spray paint that i bought (it was actually stripping the other paint off the helmet when i would spray it on), I was able to get the t-visor area painted with a new can. guess i will be emailing rustoleum about that.

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also picked this up to go with the costume.

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picked up a replacement visor for a motorcycle helmet, marked it and have it ready to cut.

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Sweet!!!:-)
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he wanted to try it on. ha

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little wet sanding and clear coat and it will be ready for the visor and padding.

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Very nice, I kinda seriously wish I could contract out an unpainted helmet from you. I'm just afraid my big noggin wouldn't fit.
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Very cool and great work :-)
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Rob - Now that is a COOL kid! :-)
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