I finally completed my project to make a scout trooper helmet. It took over 45 hours of printing time (printing at .3 mm layer height) and over 10 hours of sanding/painting/other work. It ended up costing around $55 as well. But it's finally finished! (and to boot, because it covers my mouth and nose it counts as a "facial covering" so I can wear that in stores instead of a normal mask like all the pleeebs).
The process and materials I used to make it are using modelling acrylic to fix any major issues; sanding it down, gradually getting to 400 grit sandpaper; using 2 in one primer/spray paint; painting the details with not-spray-paint; using thick foam weather stripping to add comfort and support; and using window tinting as a visor.
the window tint blurs lines a bit. Makes it hard to read but its good enough.
Now, as cool as it is, it's not perfect. There are a lot of things I would do differently if/when I make another. Mostly, I would copy the process of the youtuber 'Galactic Armory.' He makes these things for a living and has got the process down to get the speed and ease and quality he wants. Here's a quick rundown.
Use Bondo putty to hide the layer lines
Sand the bondo carefully using a powered sanding tool
use filler/primer to fill any thing missed by the bondo and to prime the surface
buy actual helmet pads rather than using weather stripping
buy a tinted face shield rather than window tint so I can see more easily
All in all, it turned out really well. It's comfy, it didn't cost too much, and it looks flipping awesome.
Here's a Loink to galactic armory: The Big Baby
Loink to video where he covers his process: Mando helmet
Here's the Money shots:
(the first two pictures are before the paint job and visor were added)
*Copyright: GavOnyx 2020. All Rights Reserved*