Halo 4 Recruit Helmet Build

[Irradiated]

I've had this pep sitting on a shelf staring me down for a few months now, so I've finally decided to get off my lumps and get to work on it. The file is the H4 Recruit helmet by JTM_Hyper ( JTM & Hyper?), which I found on the 405th pep database here. I believe I scaled it to Height=272mm (I am 6'2''), which I also believe is the default. However, it's been months since I finished it and I wrote nothing down about scaling anywhere that I can see, so that may not be accurate.

I cut it from 110lb white cardstock, and adhered most of the tabs with Loc-Tite super glue ( the normal fast-dry and the extended-dry depending on the situation ).

I used Bondo brand fiberglass resin for two coats to the exterior using 1/2'' 'horse hair' brushes. Once this dried, I began using a 'rondo' mix (2/3 resin 1/3 bondo) to seal and harden the interior. The higher resin content makes it nice and fluid and easy to rotate. It gets into all of the cracks and crevices quite nicely. I plan on doing a subsequent layer or two of rondo, most likely using a 1:1 ratio, in order to build some working thickness. My plan (assuming this project reaches fruition) is to make a silicone mold so that I may cast copies.

I also had to widen the 'head hole' at the base of the helmet as I am rather fond of my ears.

More pics and progress will hopefully be on the way soon. I welcome any comments, criticisms, or feedback of any kind.

 

[King of Gondor12]

Awesome job mate, the pep was crisp and clean, good job with the resin and rondo, can't wait to see this done!

 

[Irradiated]

Awesome job mate, the pep was crisp and clean, good job with the resin and rondo, can't wait to see this done!

Thanks!

I've managed to finish doing the initial rondo layer for the interior, along with trimming about 3/4 inch all around the 'head hole'. I made sure to build up around where I was cutting with some bondo so that it would be nice and solid to cut through. As a side note, I also learned that my decision to forgo pepping the visor was probably not the for the best. As I was casting rondo around that area, I made a complete mess of my work space, and then later realized that I would need to reinforce the area around where the visor would lay before I can really work on them, anyways. If I had included the visor, I could have simply used a dremel to cut it out after having rondo'd the interior, and then the area would have been thick and solid. Live and learn, maybe?

It's nice and spacious, but I am fairly confident that it's scaled well for my head. Any thoughts on the matter are welcome!

I'm wearing my black UA balaclava under the helmet, because I thought that it would be better to see contrast. As I look at the photos, however, I see that it might actually have made it harder. I forgot that I am the proud owner of nice, dark blackout curtains.

After I take my dremel to some of the high spots and bubbles, I am contemplating skipping a second coat of rondo and going straight to the bondo phase. I would, of course, reinforce any areas where I could cut into the helmet interior prior to doing so. I need to replenish my exhausted bondo supply, but hopefully I'll have some more progress made soon.

 

[ADAWG99]

It looks quite accurate. Can't wait to see it done.

 

[Lowcone494]

Im impressed, i usually hear about warping when people dont build the visor in with the helmet. was there any warping?

 

[Irradiated]

It looks quite accurate. Can't wait to see it done.

Thank you kindly! I'll have some time to work on it this week, so I'm hoping to make some good progress on it.

Im impressed, i usually hear about warping when people dont build the visor in with the helmet. was there any warping?

The the lower part (mouth guard?) was a bit off center. Luckily, pepakura is still pretty flexible even with two coats of resin, so I was able to straighten it out during the rondo phase. There is a little bit of warping around the visor area, but nothing that looks too difficult to rectify.

I had time to do a little bit of smoothing, but I didn't get too much done. I found out how awesome sanding sponges are, though. 10/10 would recommend.

 

[Gokussj5okazu]

Very nice work! The bends looks excellent. Take your time smoothing it and you will definitely have a quality piece.

 

[Irradiated]

Very nice work! The bends looks excellent. Take your time smoothing it and you will definitely have a quality piece

Thanks! I'm definitely trying to take the slow and steady route. I do wish I'd been able to get more progress in this weekend. The weather has not been on my side. I work in a screened-off porch area and for the past few days it's been around 80-90F and 90-100% humidity. The bondo certainly does not like moisture, so I've had some problems with curing.

The work I have been able to do is coming along nicely. I've got to make a good number of alterations to the base pepakura, but all in due time.

 

[Irradiated]

So, slow progress, but progress all the same! Some reference pics I've been looking at have a bridge between the two parts of the 'brim', I like the look so I super glued a Popsicle stick as a base for some Bondo. I've also started to try to go back over some of the sharp edges with bondo and a razor blade to try to get them nice and flat.

I almost have the side to the shape that I want it, so just a little bit more bondo work and then lots and lots of sanding. I'm trying to take a minimalist approach to bondo because in all honestly I'm not too fond of sanding.

I had a killer workout in the sun today, and I've been just exhausted since. I didn't think I'd get any work done on ye olde helmet tonight, but I found some 'liquid motivation' helped me out a lot.

Hoping I can get my sanding sponges clean and make some definite progress tomorrow!

 

[AI Blue Fox]

Good on ya! good work! love the recruit helmet. Keep it up.

 

[Mstruvmgc]

Helmet is looking great so far