WEEK #6 PROGRESS SUMMARY...
01) Designed helmet electronics circuit
02) Installed helmet electronics (Switches, lights, and fans)
03) Worked on minor helmet aesthetics
04) Completed torso fiberglass
WEEK #6 PROGRESS DETAIL...
"Improve the mind, improve the body."
Made pretty good head-way (and torso-way) this week. Having designed the circuit for the helmet electronics during the week (it took me a couple of iterations before figuring out how I wanted it to operate) I really wanted to mount and wire everything. First I made some minor revisions to the helmet including adding some rough details to the front of the visor and making the light diffusers. The diffusers were constructed using the edges of a CD case (the ridges look cool on the outside and i brushed the inside to help distribute the light from the LEDs (thanks Brandon McClain)). Right now the shades are just pressure-fitted in but after paint I'll probably hot glue them in.
I mounted the push-button switches (one for the fans and one for the lights) on the exterior...I thought this would be easiest as far as access-control and I wanted to add a personal touch to the helmet. When I went to drill the holes the space between the two proved to thin and broke out. To fix this I used painters tape to tape off the holes on the outside and to create a reservoir around the holes on the inside. I poured rondo in the reservoir and the resulting built-up material allowed me to drill the holes. The extra material also conceals the recessed bodies of the switches and keeps them held in tight.
The two battery-holders are mounted to the inside of the ear pieces. I used two-part epoxy putty to create flat mounting platforms for the holders to sit on and screw to. I also used the putty to section off the vent areas (which I drilled out) so that the air-flow is directed to and from the outside instead of recirculated helmet-air. Again, the putty allowed me to screw the fans to the helmet without penetrating the helmet-itself. One fan intakes and one fan exhausts.
The LEDs were inserted into a drilled-out section of square-dowel. I soldered the resistors to the LEDs and screwed the LED assemblies to more putty-platforms behind the light openings. I completed the wiring from the LED assemblies and fans to the switches and batteries. I have quite a bit of extra wire but it's fine for now. I used male/female wire connectors between each device so any component can be removed/replaced as necessary. All wire and devices can be removed and installed fairly easily, this way I can remove everything to finish the aesthetics and paint (I plan on spraying the interior black).
Moving away from the helmet I spent the better part of Sunday afternoon applying fiberglass to the inside of the torso piece. The strips of fiberglass mat went in much easier than when I glassed a thigh. I used a dabbing motion with the brush of resin instead of a stroking motion. Stroking served to pull the fibers apart...dabbing adds time but it's much more effective. Even so there are quite a few straggler-fibers all over the torso and although there is over-hang at the edges that need to be sanded I went ahead a prime-painted because the pepakura numbers/lines needed to be gone.
Although I'm going to tweak some minor elements of the helmet all that's really left to complete is the padding and painting. I stopped by a motorcycle apparel store over the weekend and took some photos of their helmet-liners. They didn't have much for liners-only so I intend to make the padding myself.
I've noticed an uptick in the time I spend outdoors on the weekends since this hobby has combined with the temperate months of summer. I have added sun-screen to my typical materials list. Unless I add hardening activities to weekdays I think I'll have to encroach upon July to complete the armor. Aside from a few items, I haven't addressed the under-suit really. I hope to have the helmet complete within the next two weeks.
Thanks for reading four-oh-five! Please let me know if you have any questions or comments. Until we meet again.