"Help!" for: Fiberglassing, Resin, & Bondo

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what is the minimal temperature does it need to be for bondo to cure correctly and to use spot putty?

I've used bondo at around 55 to 58 degrees or so before (I normally mix it hot though). I believe it recommended to be used at 65 degrees or higher. However, if there is good ambient heat then you can get by at lower temps than what is recommended. Like direct sunlight tends to raise the ambient heat. Hope that helps.
 
Bondo burns? Sweet...

But i have another question. I fibreglassed a helmet but in some spots the Fibre glass mat hasnt bonded to the inside and left little areas.
I was wondering is there any suggested method to fix this problem?
 
i've never used fiber glass before and i was wondering, what works better? fiberglass cloth, or resin? or are you supposed to use them together?
 
i've never used fiber glass before and i was wondering, what works better? fiberglass cloth, or resin? or are you supposed to use them together?

You use them together.

The different terms are a bit misleading here. You may have heard of "fibreglass resin", which is actually polyester resin and doesn't contain any fibreglass. It's just supposed to be used together with it, but you can use different kinds of resin (epoxy, urethane), too. Then there are fibreglass cloth and mat, the former consists of long glass fibres that are woven like textile and the latter consists of shorter fibres that are stuck together with an adhesive that will dissolve ones it comes into contact with the solvent in the resin. Which to choose is basically a matter of personal preference, but the mats won't work with solvent-free resins. As a third alternative, you can also use chopped fibres of around 5 mm length and mix them into a "paste". Or you can use Rondo, which is Bondo (body filler, polyester-resin based) mixed with (polyester) resin. Both of these are weaker than doing it "right" (i.e. with resin and mat/cloth), but stronger than plain resin. The advantage is that they can be easier to work with.

If you want to try out any chemicals, remember: Safety first.
 
quick question: what for is fiberglassing and resining works? to make the helmet hard/stiff?

Yes. It is used to make all parts of your armor hard since the cardstock alone is obviously not hard. Resin and fiberglass is just one of the methods used. Mixing a little bit of resin with bondo and adding in the red cream hardener creates what we call "rondo" and can be used instead of the fiberglass. It's an excellent thing to use for helmets since you can be sure you cover all the inside. You just pour some in your helmet and roll the helmet around to make sure it all gets covered. The stuff DOES get heavy so only try to work on a small area at a time so nothing gets warped.

Another hardening alternative is smooth on products. They are a bit more costly and from what I understand can ONLY be ordered online. It's non-toxic and can be used indoors.

Another thing I want to add is that the resin is used FIRST to make the cardstock stiff. You will brush this on the OUTSIDE of your armor pieces and will do about 2 coats just to help stiffen the paper. After that, you can then fiberglass the inside.

Hope that answers your question and then some. :)
 
Quick question, How much fiberglass cloth and resin would you expect to use on a suit of armor?

that really depends on the size of all your pieces. A person who is doing a 7 foot tall armor isn't going to use the same amount as someone who is building armor for a child.

This is where you experiment with mixing and quantity to how many pieces you can coat. Yes, this is where, you have just have to "guess".

BTW, a plastic cup of Rondo (the kind that is used at parties) can cover an entire helmet (outside) if used correctly.
 
Hi guys, long time lurker here and recently I started to make a helmet, it's the first I've ever made and I know the basics on how to do the fiberglassing, resin, and bondo. I have a few concerns though, first, the helmet is not very sturdy, its made of lots of pieces of cardboard, will just using the normal techniques for supporting it still work or will I need something more? Next, the helmet is already kind of tight, so adding fiberglass inside then padding it would make it unwearable. Is there anything I can do to make it sturdy without putting too much stuff on the inside?
 
Hi guys, long time lurker here and recently I started to make a helmet, it's the first I've ever made and I know the basics on how to do the fiberglassing, resin, and bondo. I have a few concerns though, first, the helmet is not very sturdy, its made of lots of pieces of cardboard, will just using the normal techniques for supporting it still work or will I need something more? Next, the helmet is already kind of tight, so adding fiberglass inside then padding it would make it unwearable. Is there anything I can do to make it sturdy without putting too much stuff on the inside?

The thickness of fibreglass is practically negligible. This stuff is really sturdy. Padding is another matter; If you helmet is too tight, you may have scaled it wrong (or not at all). That's a frequent mistake everybody makes, especially at the beginning. Don't take it too far if you have doubts about the size, wrong size usually can't be fixed later. Not on helmets, anyways. Don't add anything on the outside except the first few resin layers and small amounts of Bondo, otherwise you'll lose all the detail your model has right now.

Whether it will survive resining depends on what kind of cardstock/paper you used. 220 g/m² or more should provide sufficient stability, and to make absolutely sure, some models ave support struts. If yours doesn't, just improvise and add some yourself.
 
I've spent countless hours in prep for my first helmet. All went well throughout pepping and gluing, now I'm at the resining step and I fear that I have put on too much. I did the process in steps (per Ben Streeper's videos) and tried to brush it on thin, but I fear I may have put way too much on. It is dry, but there is a strong smell of resin.

Needless to say, I kept the respirator on and have left it outside. This can't be normal, right? It's supposed to stop with the odor after the stuff dries. I'm at a loss at what to do and I'm also wondering if resining too much can hurt the helmet in the long run?
 
Well, too much resin can warp the piece, but that's pretty much it. The resin will still smell after curing, but it won't be really strong. If it's dry to the touch, it's fully cured and safe. If not, give it some more time.
 
Well, too much resin can warp the piece, but that's pretty much it. The resin will still smell after curing, but it won't be really strong. If it's dry to the touch, it's fully cured and safe. If not, give it some more time.

Thank you for the help. I can breathe a little easier now that I know I didn't ruin it.
 
Just another NOOB :/

Hey guys, I'm a huge noob to this all, yes even this forum stuff this is actually my first membership to one. Well I've been looking around trying understand where exactly things are around here because i know people tend to get a little testy about posts and what not.

Anyways since I'm new I decided to start small. I'm going to hold off on doing any armor pieces until i get a little more acquainted with sizing and all that stuff.

So my first project is the Halo Reach Knife that is used by the characters online, NOT EMILE'S, using pepakura. I feel it's coming together nicely for my first, still not done piecing it together, however I'm slightly confused do to the tutorial videos i watched. (can't remember the source but i'll find out) He started with a helmet for the pep build and then jumped to a gun for the resin, and to a different helmet for the fiberglass.

Now that just threw me off a bit seeing he jump from project to project in each video. So I was just curious, seeing as you can't resin both in side and out side of a weapon, am I to believe you only resin the weapon on out side of course? And here comes the dumb part, do i not fiberglass it, and do I still use the bondo putty and sand it?

Any help would be appreciated and i'll get my source as soon as possible he was a tremendous help just lost me on the change up between projects. I understand this is very tedious work and that i would have been hard for him to make tutorials on one project.
 
@KYgeLE88
For the knife, it's best to resin the outside to maintain some strength, but fiber glassing the inside will be too difficult, so it's recommended that you put a small hole in the hilt of the knife and pour rondo in it to harden it. Rondo is resin and bondo body filler mixed together to make a liquid type hardener. After that's applies, you can bondo the outside of the knife for detail.
 
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