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Old 10-01-2015, 05:05 PM   #1
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Default My son's halloween costume

Now that my armor is done, I have used halloween as an excuse to make luke his. He picked a mandalorian armor as his kit. So i got started.

Been working on the helmet for the last month or so. Started using a pepakura file. I used cardstock as my medium, cut it and glued it together.



After I got it where i wanted it, I put resin on the outside and fiberglassed the inside.



Once that dried, I bondo'd the outside and sanded it smooth.


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Old 10-01-2015, 05:06 PM   #2
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Default Re: My son's halloween costume

once that was done, I put a coat of primer on it just to make it look better



Then it was time to make the mold. I went the cheaper route and just used silicone from Home depot.



Then it was time for the mother shell. Made from fiber glass.



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Old 10-01-2015, 05:07 PM   #3
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Default Re: My son's halloween costume

when the mothershell dried, it was time to remove the pep helmet



Then I started slush casting helmets from it.



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Old 10-01-2015, 05:07 PM   #4
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Default Re: My son's halloween costume

so now i get to do some sanding, painting and such. can't wait.

here's the Orioles themed paint scheme we are going with.

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Old 10-01-2015, 05:43 PM   #5
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Default Re: My son's halloween costume

Use the force, Luke
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Old 10-01-2015, 06:39 PM   #6
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Default Re: My son's halloween costume

Vary cool
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Old 10-02-2015, 06:37 AM   #7
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Default Re: My son's halloween costume

that's so cool, it's looking great
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Old 10-02-2015, 07:46 AM   #8
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Default Re: My son's halloween costume

Very cool!
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Old 10-04-2015, 03:21 PM   #9
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Default Re: My son's halloween costume

thanks

did some sanding clean up last night and cut out the t-visor area. got luke to do a little modeling.



went to home depot today and got the paint. going to do an under layer of hammered silver and use the vaseline technique so that you see the metal look under the battle damaged areas of the armor.

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Old 10-04-2015, 03:29 PM   #10
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Default Re: My son's halloween costume

Little short for a stormtrooper isn't he?
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Old 10-04-2015, 03:34 PM   #11
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Default Re: My son's halloween costume

Holy snikes, count me impressed! Fine job, sir!
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Old 10-05-2015, 07:18 PM   #12
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Default Re: My son's halloween costume

started painting today. first was the primer and then the hammered silver paint.


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Old 10-08-2015, 01:41 PM   #13
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Default Re: My son's halloween costume

Cool!!
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Old 10-08-2015, 06:16 PM   #14
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Default Re: My son's halloween costume

Will you be my Dad?
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Old 10-10-2015, 12:31 PM   #15
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Default Re: My son's halloween costume

well. after having a heck of time with the first can of orange spray paint that i bought (it was actually stripping the other paint off the helmet when i would spray it on), I was able to get the t-visor area painted with a new can. guess i will be emailing rustoleum about that.



also picked this up to go with the costume.



picked up a replacement visor for a motorcycle helmet, marked it and have it ready to cut.

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Old 10-12-2015, 11:38 AM   #16
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Default Re: My son's halloween costume

Sweet!!!
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Old 10-12-2015, 01:20 PM   #17
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Default Re: My son's halloween costume

he wanted to try it on. ha



little wet sanding and clear coat and it will be ready for the visor and padding.

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Old 10-12-2015, 05:00 PM   #18
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Default Re: My son's halloween costume

Very nice, I kinda seriously wish I could contract out an unpainted helmet from you. I'm just afraid my big noggin wouldn't fit.
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Old 10-12-2015, 05:35 PM   #19
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Default Re: My son's halloween costume

Very cool and great work
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Old 10-12-2015, 06:33 PM   #20
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Rob - Now that is a COOL kid!
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