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  1. Rep:
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    My Guy-Manuel helmet [LEDs incoming]

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    Hello, this is my first post (second actually, since the first didnt make it to the forums )
    in this post im going to show how i made my helmet.

    I started up with the pepakura file, printed and started mounting it:
    http://a4.sphotos.ak.fbcdn.net/hphot..._3710604_n.jpg
    http://a3.sphotos.ak.fbcdn.net/hphot..._7537928_n.jpg
    http://a5.sphotos.ak.fbcdn.net/hphot...0_347428_n.jpg

    with the basic shape, i used fiberglass on the inside (resin+fiberglass cloth) in order to have a hard structure. after that, i started using bondo / sanding on the outside to make the curves
    http://a6.sphotos.ak.fbcdn.net/hphot..._4833286_n.jpg
    http://a2.sphotos.ak.fbcdn.net/hphot..._2030329_n.jpg
    http://a3.sphotos.ak.fbcdn.net/hphot..._3377033_n.jpg
    http://a3.sphotos.ak.fbcdn.net/hphot..._3084981_n.jpg

    Then, i cutted out the visor part, so i could start working on the visor and for better handling of the helmet and procceded the bondo / sanding
    http://a2.sphotos.ak.fbcdn.net/hphot...71_91995_n.jpg
    http://a4.sphotos.ak.fbcdn.net/hphot..._5578304_n.jpg
    http://a3.sphotos.ak.fbcdn.net/hphot...8_864487_n.jpg

    I went throught many problems while doing the visor, since i didnt have a propper vaccum former machine that would fit the visor, i had to do part of it manually with a thermo blower
    http://a4.sphotos.ak.fbcdn.net/hphot...57993595_n.jpg
    http://a3.sphotos.ak.fbcdn.net/hphot...57513098_n.jpg
    http://a5.sphotos.ak.fbcdn.net/hphot...96708200_n.jpg
    http://a2.sphotos.ak.fbcdn.net/hphot...52617170_n.jpg
    after many tries, i finally got one visor to be ennouth thick and without many cracks
    http://a1.sphotos.ak.fbcdn.net/hphot...15712470_n.jpg
    http://a6.sphotos.ak.fbcdn.net/hphot...74208434_n.jpg

    then, i went back to the infinite filling / sanding, now with another product, wich dries faster and leaves no air bubbles on the surface, it also doesnt require the cathalizer, wich made its use way faster
    http://a8.sphotos.ak.fbcdn.net/hphot...23718811_n.jpg
    http://a2.sphotos.ak.fbcdn.net/hphot...34288775_n.jpg
    http://a4.sphotos.ak.fbcdn.net/hphot...30227465_n.jpg
    holes fot the back wires
    http://a5.sphotos.ak.fbcdn.net/hphot...95449028_n.jpg

    then, I painted the visor with a permanent marker on the inside, a very cheap way to make it look smoked, visibility is not that bad, but ill have to remake the visor when i need to put the led on it
    http://a4.sphotos.ak.fbcdn.net/hphot...96358214_n.jpg
    http://a6.sphotos.ak.fbcdn.net/hphot...20564111_n.jpg

    while waiting between layers of filler to dry, i started working on the glove plates, i used the PET from the visor sheets and warmed them on a curve pipe to match the hand
    http://a3.sphotos.ak.fbcdn.net/hphot...17651336_n.jpg
    http://a8.sphotos.ak.fbcdn.net/hphot...39629990_n.jpg

    After more sanding, i finally painted the helm with primer and then sanded it again to paint it with auto paint (chroming is too expensive in brazil )
    http://a6.sphotos.ak.fbcdn.net/hphot...36026510_n.jpg
    http://a8.sphotos.ak.fbcdn.net/hphot...05583159_n.jpg

    After the painting!
    http://a7.sphotos.ak.fbcdn.net/hphot...42343766_n.jpg
    screws to attach the inside of the helm
    http://a2.sphotos.ak.fbcdn.net/hphot...01438035_n.jpg
    http://a4.sphotos.ak.fbcdn.net/hphot...85667690_n.jpg
    then place the visor...

    Helmet done! (for now)
    http://a7.sphotos.ak.fbcdn.net/hphot...70459256_n.jpg
    http://a2.sphotos.ak.fbcdn.net/hphot...97121443_n.jpg
    http://a3.sphotos.ak.fbcdn.net/hphot...67497291_n.jpg
    http://a2.sphotos.ak.fbcdn.net/hphot...84215626_n.jpg

    the whole build took 2 months (since it was the first time i ever tried to build anything)
    thanks for reading!

  2. Rep:
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    Re: My Guy-Manuel helmet [LEDs incoming]

    In case you are lazy, here's a final pic of how its looking:


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    Re: My Guy-Manuel helmet [LEDs incoming]

    this is the best pep build I have seen without making a cast out of it. AWESOME JOB! I love the overall shape and contours of the helmet!!!!! Very, very nice job.

  4. Rep:
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    Re: My Guy-Manuel helmet [LEDs incoming]

    thanks for your feedback!

    it's really a shame that i couldn't chrome it (too expensive in Brazil)
    and that i didnt make a silicon mold of it back on the building proccess.

    anyway, i feel very proud of saying that i did it all by myself

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    Re: My Guy-Manuel helmet [LEDs incoming]

    Quote Originally Posted by Blitzkin View Post
    thanks for your feedback!

    it's really a shame that i couldn't chrome it (too expensive in Brazil)
    and that i didnt make a silicon mold of it back on the building proccess.

    anyway, i feel very proud of saying that i did it all by myself
    The best feeling for me is when somebody says" how did you make that????"

    And I'm like, "..............I made it with paper."

    Anyway, great job. I love the paint too. Mind telling me what it is?

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    Re: My Guy-Manuel helmet [LEDs incoming]

    It looks awesome!

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    Re: My Guy-Manuel helmet [LEDs incoming]

    It looks nice, but I think you should redo the visor with a vacuum former. There looks like there is a flat spot near the top.

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    Re: My Guy-Manuel helmet [LEDs incoming]

    Thanks for the support guys!
    The paint is a metalic golden, i bought on a car shop and painted with a airbrush then sealed it

    i actually made the visor on a vac former, but it was too small so i had to do the corners and overall shape with a thermo blower that heats up to 650ºC (i used 240ºC tho, i just find impressive how hot that thing could be ^^)

    ill redo the visor in order to place the leds, so ill work on a smother base mold for it

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    Re: My Guy-Manuel helmet [LEDs incoming]

    The helmet is so amazing! Good job! By the way the first picture with the kitten is so adorable, haha.

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    Re: My Guy-Manuel helmet [LEDs incoming]

    great job man!! if only u had it chromed, it would be that more awesome!

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