Pipninja's Ultimate Gungnir Helmet!

Time for another update! We have a bunch of assembly today! But before that, I got the chipped highlights done! I take this chrome paint pen, and a small silicone brush, and just add a really bright silver highlight in the middle of the zinc paint chip areas.

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From there it was on to adding the heat press inserts!

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I did learn a few lessons for heat press inserts:

1: add more tolerance in the holes that the bolts pass through

2: add registration for the threaded inserts for the smaller side. This is especially important for the ones I have to put in at an angle.

3: make sure there is no residual plastic or support inside the hole to press. It can jam the threads if you don't check the hole first!

From there assembly bagan!


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The visor ended up needing these little foam standoffs to account for the longer bolt, and allow for more tolerance in the holes in the visor.

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Something to note here, I did cut out a hole in the visor behind the fans that allowed them to pull air from the cbrn vents

Now it's on to electrical! I got the electrical done on the upper light!

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So the red light is my in helmet indicator, so I dulled the light down by dusting it with black spray paint. These are my tests with the red led

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Javier Bardem Wtf GIF by Warner Bros. Pictures
Lisan Al Gaib!
 
Another update!!! Today was front hood electronics!!!

First, I started with the mics for the hearing, and then I isolated them and put the speaker in.

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Next it was on to the front speaker for the voice amp

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From there I could put in the rest of the wiring, starting with the left side, and then the right!


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I went on to test the parts I could, being the screen and the fans by plugging in the 12v power. All the fans worked, the lights worked, the red light was sufficiently dim that it didn't light up my face, and the night vision on the camera even worked! All in all, the systems I could test worked perfectly!

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Now I just have to get the back plate done, which should get off the printer tomorrow, and do the final control electronics, the padding, and sand, smooth, and paint the back plate! All before Friday!!!
 
So I think I've made a padding decision. Originally I really wanted to make my own, but since I am u
Severely limited on time, I think I'm just going to buy a helmet padding kit! It would also probably be more comfortable in the long run

I am going to go with this one:

Yzpacc Tactical Helmet Pads, Universal Replacement Ex Helmet Internal Memory Foam Pad Universal Helmet Padding Inserts Protective Mat for ACH Mich Team Wendy Fma EXF Helmet Military Fast Amazon.com
 
So I have started the journey to make the ultimate Gungnir helmet! I am going to be 3d printing the helmet, with a vacuformed lower visor, and camera system, as well as an assisted audio system, like my current helmet! I also plan to mold and cast the neck gasket in rubber.

I pulled some orthographic views of the in game model from blender, and am modeling in fusion 360. I have been learning a lot of the surface and form tools, and so far it's coming out! The first step I made was the hood.

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This is where I have got in the past two days of work! I am so happy with how it is coming along, and this is going to be a truly epic build!

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So do you think you will be able to get the helmet done before the con this weekend?
 
Okay, so Washington gaming expo is finally completed, and spoiler alert, I did get to finish the helmet in time! So let's rewind the clock to show the build!

I'm going to break this up in multiple posts so I can keep track of all the photos!

First off, the back of the helmet finished printing! This was the crux of waiting to get the last of everything done!

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From that, I popped the supports off and did a test fit

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From there was priming and sanding

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Then on to painting, starting with the zinc coat, and then the masking fluid and top coats!

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For the stencil, normally I would use my cricut, but it was down, so I actually manually made the stencil by using some thin masking to measure out and guestimate the side box stencil

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From there, it was instillation of the top light

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From there, it was a full fitting

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Now that all that was done, it was on to the technical parts, the electrical!

So first off, here were the electrical control boards that I had to install together. Having a colored electrical diagram was beyond helpful here!

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The first step was fitting the control boards in, and then tacking them down so I could put on the cover plate

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I made sure that I labeled all the wires before putting the cover plate on!

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From there was soldering the plug connections. Having really long and maneuverable helping hands was incredibly invaluable here!

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Then the focus was on this little plate, behind which was supposed to be power distribution. I tested the battery fit here.

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The reason I say supposed to, is because we ran into a little trouble here. Amazon sent me the wrong buck converters, so I only had this step up converter, and I needed a step down converter. With that, I ordered a new one, and pushed forward with what we had.

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At this point, I actually finished the helmet all the way for day one of Washington gaming expo, but for the sake of keeping it organized, we are going to jump ahead first. The new buck converters came in Friday afternoon, and I was able to put them in, and get at least the hearing working. This is another time where the long nimble helping hands were great!
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After getting these installed, I put the cover plate back on, and the electrical was completed for the helmet.
 
With the electrical done, it was on to finishing the helmet! Starting with final assembly

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Now on to the best part, weathering! Starting with a chrome dry brush!

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Next it was on to the wash. I prefer a darker muddy brown than a black or grey wash. I'm going for slightly thicker than milk consistency, and then I cover the entire piece in it before I start cleaning it up. I then dab paper towels to pick up mose of that wash, but leave behind a fair bit of grime.

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And here is the finished helmet!
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The last thing I did was add the padding!

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And a final camera test

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SUCH A COOL HELMET!!

I must ask, did you have any trouble running the fans and hearing/speaking system off the same battery? Did the fans cause interference or anything? I think the fans in my helmet could be causing a problem with the hearing assist system I have.
 
SUCH A COOL HELMET!!

I must ask, did you have any trouble running the fans and hearing/speaking system off the same battery? Did the fans cause interference or anything? I think the fans in my helmet could be causing a problem with the hearing assist system I have.
Nope, everything is in parallel, and the speech and hearing have their own step down boards. I e had no cross connection issues at all. It might be that that step down board regulates its output, Because all of my fans run off of a higher 12 volt then the 3V of the hearing board. As far as the voice amp goes, I'm still trouleshooting feedback right now so it's not technically working
 
Nope, everything is in parallel, and the speech and hearing have their own step down boards. I e had no cross connection issues at all. It might be that that step down board regulates its output, Because all of my fans run off of a higher 12 volt then the 3V of the hearing board. As far as the voice amp goes, I'm still trouleshooting feedback right now so it's not technically working
Good to know!

As for microphone feedback, I had trouble with that all of last year. The microphone I was using was able to pick up sounds that were quite far away, including it's own output from the speaker. I replaced it with a mic that had a much shorter throw, which helped a LOT. It may not be your solution, but it's at least worth pondering. Feedback isn't always a speaker placement problem I guess
 
Your weathering looks so good
And actually doing a blind helmet but using a screen is crazy ambitious, huge kudos
I'm curious if the screen is disorienting and how's the depth perception?
 
Your weathering looks so good
And actually doing a blind helmet but using a screen is crazy ambitious, huge kudos
I'm curious if the screen is disorienting and how's the depth perception?
It's not disorienting at all, and the visor helps for the really up close depth perception
 
Not to take away from the incredible electronics, because wow (also I love how clean everything is inside!), but this is an absolutely masterful example of painting and weathering. It's so impressive!

(Also, late to the party on commenting, whoops!)
 
Not to take away from the incredible electronics, because wow (also I love how clean everything is inside!), but this is an absolutely masterful example of painting and weathering. It's so impressive!

(Also, late to the party on commenting, whoops!)
Thank you!! Eventually when I finish the model tweaks for the final design, I'm going to be putting together a YouTube series on the helmet build!
 
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