Hey guys,
First of all, let me say hi and thanks for everyone who participated in the 450 pages from the tips thread.

So here's my first take at a Thomas costume. The helmet is too big but since it is my first try, it will do for this Haloween.

Pepakura and cans


My cheap 20$ coat with the studs from two studded belts (man, de-studing was a pain in the ass!)


First fit try


Opera gloves and plastic sheet warped with a heat gun


Resin, fiberglass and Bondo!


First rough sanding


Getting there...


Some coats of black Lacquer


First coat of paint


I had to try the visor


And try everything together :P


Very happy from the result!


I still have work to do; more light coats of paint, installing the leds, foam padding the helmet. But at last I can see the end!