Jorge Helmet Build--Very First Attempt at any of this!

[tlooney2]

Hey 405th,
Glad to finally be able to post, right as I stumbled onto this website and started gathering information about this whole process the Flood attacked it and shut it down. But before it did I managed to snag some information on beginning. So here it is, the first pics at my attempt at this.

Jorge Helmet by "Reclaimer"

After I printed out every page of the pep I realized that I had not printed the numbers on the inside of the flaps so I had to go through and write each one in. Needless to say, I was not happy.

No visor or ear piece, maybe a little large but this is my first one and who knows, i do have a very large head.

Finished pep work

Right before the Resining stage--- My friend Jonathan aka ThunderCat

Finished resining the outside.. little deforming, especially around the nose area.. just have to shape with bondo....(turns out that is not a good idea, good pep work leads to good bondo/resin work)

Beginning bondo stage

First layer of bondo done and sanded, just gonna have to go back and finely sand the rest.

 

[Spartan_127]

First off . . . . Looking good so far. As far as sizing, it looked good. You have to remember that you'll be putting padding and other things in it as well so that it's wearable.

I don't see anything that can't be fixed with another light coat of bondo or some glazing putty. Sometimes you have to add more than one coat if you find a lot of air pockets or dimples after initial sanding. Most of the time, less is more with bondo. . . LOL! Work in small sections and focus on making it as smooth as you can to start off with to save you a lot of sanding and wasted material in the long run. By the look of your last couple of pics, it may be bast to just add some more bondo in to smooth it out a little more. Just remember that the more you add, the heavier it will be.

I didn't see any obvious warping in your pics either, so kuddos for that. Also, looked like clean pep work. Keep up the good work. I'll definitely keep an eye on this Jorge build. Are you planning on doing a dull set of armor or just the helmet?

 

[Carpathia]

You've got a good start here. There's just one thing I have got to point out, the mask you're using while you resin is the wrong kind. If you plan on doing any other projects using resin and body filler, you will want to invest in a respirator that looks something like this...

...and is rated for organic vapors. Rule of thumb, if you can smell the resin while you're working, the mask isn't doing the job. I can't stress that enough, safety should be first.

Beyond that, good work, keep it up!!

 

[Road Kill]

wow its looks pretty good so far man
keep up the great work

 

[Redshirt]

Welcome to the 405th. You're off to a solid start on a nice Pepakura foundation. Sometimes less is more with the Bondo. Some of your initial application looked a little thick and rough on the surface. This usually comes from continuing to try and apply the Bondo after it sets. A layer of Bondo has to be sanded down to the lowest pit or hole to be smooth. I would mix smaller batches--even as small as a Dixie cup. If it starts to thicken, put it down. It's false economy to try not to waste it as it sets. The end result of trying to quickly apply partially set Bondo is always chunky and thick, requiring a lot more sanding. Keep it up.

Redshirt

 

[Croc co]

nice job with the jorge helmet,youve gotten further than i ever have with anything

with printing and pepping i learnt to have the numbers on the outside of the model your pepping
anyway good job

 

[tteape0]

First one of these I have seen. Looking good.

 

[misfitjh]

Looks good, the only thing I would suggest is going lighter on the bondo. Keeping it light requires less sanding and uses less product.

 

[tlooney2]

Thanks for all the replies! Yeah, I only had read a small amount about bondo before starting. Then found a great tutorial about using a small amount of it in one area before moving on. But as with everything, you learn more from your failures then your successes? I put on a very small layer of bondo last night that only filled in the holes. I was definitely putting it on after it was getting to the stage right before it hardened fully.

In reply to Spartan_127;

I am definitely hoping to get a full suit of armor done. But it will not be a true "Jorge" armor, I want to do some sort of etching on a plexiglass sheet for a tactical pad and illuminate it from the side like Ive seen in other builds. And I was thinking of putting a pair of turtle beach headphones that amplify the sound around you while still playing a game right into the ear piece and wire the mic to right in front of the mouth. I feel like that would be boss lol.

Ill put up a few pic's later today of the progress I make today.

Again, I would love some constructive criticism. Any suggestions on applying the bondo? I've been using a putty knife, then last night 2 old game stop cards went to the "chopping board" and were used. They definitely seem like they are better for pulling a small amount of putty into the smaller holes. I've seen some different posts about what people use, but after ive put this amount of bondo maybe im using the wrong type, they are a thicker plastic type from Wal Mart.

 

[Carpathia]

Again, I would love some constructive criticism. Any suggestions on applying the bondo? I've been using a putty knife, then last night 2 old game stop cards went to the "chopping board" and were used. They definitely seem like they are better for pulling a small amount of putty into the smaller holes. I've seen some different posts about what people use, but after ive put this amount of bondo maybe im using the wrong type, they are a thicker plastic type from Wal Mart.

Many people here, myself included, use these...

You can find them in the same area you find your bondo, since they're made to spread bondo. You can cut them in to whatever sizes you need. I generally cut them into sizes ranging from 1/2" to 2" so I have a variety of on-hand spreaders. Also, they're made from a semi-flexible plastic, so it conforms fairly nicely to the surface of your piece. Clean up isn't all that bad either. You can either wipe the uncured bondo off right after you use it, or let the bondo cure and break it off cleanly. The only problem is if you get some bondo that has no hardener in it, then cleaning it is tedious. But, they're cheap and you can always pick up more.

 

[tlooney2]

Many people here, myself included, use these...

You can find them in the same area you find your bondo, since they're made to spread bondo. You can cut them in to whatever sizes you need. I generally cut them into sizes ranging from 1/2" to 2" so I have a variety of on-hand spreaders. Also, they're made from a semi-flexible plastic, so it conforms fairly nicely to the surface of your piece. Clean up isn't all that bad either. You can either wipe the uncured bondo off right after you use it, or let the bondo cure and break it off cleanly. The only problem is if you get some bondo that has no hardener in it, then cleaning it is tedious. But, they're cheap and you can always pick up more.

Good eal, im headed to wal mart after I get out of this class. Like I said, today i should be posting pictures. My goal is to be done with bondo by this weekend! (probably a noble goal)

 

[Last Resort]

So far, so good man! Gotta say though, not having the numbers printed on the sheets must have SUCKED. I probably would've just rage-quitted, chucked all the paper and just re-printed it.

As carpathiavh99 said (why do you have such a difficult username?!), getting an actual respirator is a good idea, although I can't say much, since I went without one of any kind for more than a few months before I bothered to buy one. The whole 'If you can smell it, it's probably killing you' thing is a good gauge - I used a fan stationed behind me to blow the fumes away from me, and it worked...pretty well, I guess.

Anyway, keep up the good work, it's looking SWEET!

 

[Spartan_127]

I use the spreaders Carpathiavh99 put up a pic on for the big stuff. I have another set that I've cut up into smaller strips for small stuff and I even found myself using a regular old playing card like CerealKilll3r uses in his vids. And to add on to what Carpathiviah99 said about the cleanup. . . it is a pain sometimes to clean up the uncured bondo or bondo without hardener rather. I found that Xylol (a type of paint thinner) works extremely well for getting rid of bondo without hardener. Just make sure you're using old shop rags for cleanup. Hope this helps.

 

[tlooney2]

UPDATE!

Well, got the whole thing sanded down pretty good... or so I thought. I cant seem to get the very small holes sanded out. Or should I use more bondo only in those areas? Ill post pics and hopefully will get some feedback!

By the way, went by a local yamaha dealer and bought a visor, which means I am getting pretty close? lol

 

[Spartan_127]

Those holes that you have were most likely air bubbles caused from when it started to set up and thicken and you may have kept trying to apply it on there. With the number of holes and places that you have, I'd recommend just putting another light coat of bondo on just those areas to fill them in. If you just had a couple of spots you can just use spotting /glazing putty to put on there and let it dry to smooth them out. Don't let it get you down though. The detail portions of adding bondo is a repetitious and time consuming process. If you really want to know what you need to hit again with bondo or spot putty, spray the helmet with primer and it will really point out the areas that need attention. Hope this helps. Keep up the good work.

 

[Redshirt]

The small spreader is best, especially for a helmet. Some places, like NAPA sell the spreaders 'open stock.' Just ask at the desk, and they will sell you as many of a given size as you like. I keep six of the small ones in a stack and mix about a Dixie cup's worth at a time. Spread the Bondo out, toss the spreader aside and start mixing the next batch and using a new spreader. By the time you've used your last spreader, the Bondo on your first spreader will be cured, and will just flake off when you flex the spreader.

Redshirt

 

[tlooney2]

Small update here. I have sprayed a layer of primer on to highlight the areas that need some bondo/sand work. And my oh my does it need A LOT! Started on the left side of the helmet and am only working in small stages.

I also have cut out the nose and vent pieces. The nose I am going to try sculpting with sculpey clay? (anyone have any suggestions on another material?) But also the small "vents" on the side of the chins I am going to put grate like plastic there and hopefully after I put the computer fan in there it will help with not fogging up the visor. Todays plan is to help my friend resin his scout helmet, rondo the inside of mine and finish the back of bondoing mine.

 

[Spartan_127]

I don't really know much about the details on the Jorge helmet. Do you have a reference pic of the part you say you will make out of clay on the nose? I know you achieve almost any detail out of bondo or rondo if you take the time. I don't know if the clay would adhere and stay on the rest of the helmet or not. I guess it would depend on the type of clay. Magic sculpt works really well, but can be pricey depending on who you buy from or if it is available around where you are.

 

[tlooney2]

Well, it has been awhile since I have posted. School and work tend to get in the way of things...

But I have gotten the helmet maybe 90% done. It hasnt turned out as good as I hoped. But Im positive that the next build I make will be better since I have learned alot.

But here are some updated pictures!!

With this helmet if you look at the slots on the lower parts of the side of the helmets I am going to be putting a LED in both of those areas. Also going to post a sketch of what I am hoping to do with em. And probably put a set of Turtle Beach headphones for when I play halo 4 online I can wear the helmet while playing!
I'm starting on pepping the chest piece tomorrow and drawing up plans for an undersuit. I am definitely using this as a learning experience to get better and hopefully be producing higher quality pieces.

 

[Kuroshoku]

Really nice helmet , i love the colors you chose.