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Table of Contents
Halo ODST Armor: Helmet - Part 1 of 5 of ODST Armor Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Author:vv_767 ODST
I like making stuff when I have the time. But It is soooo hard to find TIME...
Image Notes
1. this is our reference photo
Image Notes
1. This is our reference picture
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. The Pep process begins.
Image Notes
1. Paper model complete and size looks good.
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1. Details added using dremel
Image Notes
1. Just needs a lense
2. Used a scouring pad in this area
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Helmet on me. Fairly comfortable. But needs better air circulation
Image Notes
1. Get used to this program.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Taste and smells better that ketchup or mustard.
Image Notes
1. You can color code the parts.
2. Card Stock
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Looks good? OK, Print. NOTE : If you are promted to change the scale before printing, DON'T .
If you purchased Pepakura designer, save your work.
Look at that glorious stack of card stock paper...
Image Notes
1. If you are making this model you better be darned advanced and experienced in
Pepakura. If not it will make you pull your hair out.
Image Notes
1. Master Chief. Oops, wrong project
Image Notes
1. This is the model I used.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. The Pep process begins.
Image Notes
1. Started from the top
Image Notes
1. Started on a new helmet using a different model and a smaller scale.
Image Notes
1. Too Big and not even complete yet.
Image Notes
1. Remember I said you may end up scaling too big or too small. I scaled too big
and had to start over with a smaller scale. The two peps to compare size.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Elmers glue works fine
Image Notes
1. Paper model complete and size looks good.
Image Notes
1. Almost complete
Image Notes
1. Some details are left out. I will add them later.
2. Some details are left out. I will add them later.
3. Missing detail will be added later
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
dangerous chemicals.
2. Epoxy resin. General use fiberglassing EPOXY works great. It has very low odor (smells mildly like popcorn), not as toxic, and is strong. Biggest issue is that it is
expensive. A quart will run about $25.
3. Wood Glue is also cheap and is available everywhere. It is non-toxic. Has no odor. Requires no mixing of chemicals. You just brush it on and let it dry. Only issue with
it is that it is not as strong. Also, becuase it is water based, too much of it may warp your helmet. Once dry, it is waterproof. This is the method I used for the the helmet in
this example.
** Note: I have used all three methods above. There is a fourth method called AquaResin. Never tried it. ***
Image Notes
1. Several coats of elmers wood glue outside. Can also coat with epoxy resin or polyester resin.
2. No fiberglass on the outside or you will loose all the details of the model.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Fiberglass cloth. Cut to right shape and sizes.
Image Notes
1. I like using cloth instead of mat.
Image Notes
1. This is my Halo CQB Helmet Pep with some fiberglass inside
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Tap Plastics brand general use epoxy.
Image Notes
1. General purpose epoxy. 1:1 mix ratio by volume.
2. I like fiberglass clothe better than mat.
Image Notes
1. First layer done. Notice my sharpie mark? I have a nice clean edge.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. About 5 hot glue sticks should be enough.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. This is three layers of casting resin. I think two would have been enough.
2. Notice the bubbles... That is because it was raining and very humid when I did
this on my patio.
Image Notes
1. Got this from Hobby Lobby.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Front dome with 3 layers of Bondo and sanding between layers.
2. The edge is rough and uneven. I will fix this later
Image Notes
1. get the "Gold" stuff. It sands better. Get the largest tub you can afford.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Back of dome. 3 layers and sanded.
2. Edge is rough and uneven. This will be fixed on the next step.
Step 11: Making It Even And Smooth With MUD (a.k.a. RONDO)
The front and back rim of the dome is not even. The paper itself has warped a little so that both front and back rim is angled wrong. I can fix this by adding several layers
of bondo and sanding it. After several layers with lots of sanding in between I am sure I can make the rim look very even and flat.
But that is a lot of work. I have a much faster method.
This method is called "RONDO" or "MUD". It is basically thinned out Bondo that can be poured and is self levelling. It works best on areas of the armor that is flat and
wide.
The recipe is simple. Mix equal parts Bondo and fiberglass resin (polyester resin). Mix it in a plastic cup until it is the vescosity desired. Then add catalyst. The catalyst
amount should stay the same. BUT before doing this, prep your part by building a dam.
To build a dam get some 1 inch wide masking tape and fold one edge onto itself so that 1/3 of the tape is not sticky. Stick the tape onto the part to build a dam that will
hold back the rondo/mud. Add extra layers of tape on areas of the dam that looks like it will need reenforcing. Secure the helmet so that the part that will hold the
rondo/mud is flat, level and even. Mix the batch of rondo as described above.
Pour the mud. Move the mud around so that it is completely filling the dammed up area and is even.
Wait for the mud to cure. it will take about an hour.
Remove the tape and sand.
Image Notes
1. Rondo or mud
2. I use the GOLD Bondo. it is easier to sand.
Image Notes
1. Mud poured.
Image Notes
1. Mud dam
2. Helmet secured to the table with lots of tape.
3. Helmet is secured to table with lots of tape.
Image Notes
1. Rondo / Mud cured. Nice and flat!
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Blue line indicates where the dam will be placed..
Image Notes
1. This detail of the helmet would be a pain to Pep. so I opted to build it up with
Rondo.
Image Notes
1. Mud dam area
Image Notes
1. Another section of the helmet where rondo/mud was used. After the rondo
cured, I sanded it down to match the contour of the helmet.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. This detail was also added using Bondo and resin mix (rondo). The detail could
have been done with Pep but mud was a lot quicker and stronger.
Image Notes
1. Rondo / mud cured. did some light sanding to create a curve to follow the
contour of the helmet.
Image Notes
1. Low spots filled in with bondo and sanded smooth.
Image Notes
1. Blue areas are low spots that need to be filled with bondo
2. Hard to see but this whole area is blue.
3. Some spots I will leave pitted and imperfect like areas indicated by arrows. I will
do something with these damaged areas later.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Pencil marks.
2. Pencil is great. If I need to adjust I just erase and start over. Not so easy if
marker was used..
Image Notes
1. Details added using dremel
Image Notes
1. A steady hand and a new cutting wheel makes quick work of the details.
2. Cutting wheels, I have lots on hand.
Image Notes
1. Back of head
2. I left damaged areas of bondo alone on random spots of helmet.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. I had chocolate pudding on these silver "chipped" areas.
Image Notes
1. Three layers of primer with light sanding between coats.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Just needs a lense
2. Used a scouring pad in this area
Image Notes
1. Notice that the chipped area is a dull silver. I gave the whole helmet a light
mist of flat black paint to remove the shine.
Image Notes
1. high-speed cutter
Image Notes
1. Swiss Miss chocolate pudding was used to mask this "chipped paint" area.
2. Once the paint dried, I just wiped off the pudding with a damp cloth. Smells
better than ketchup or mustard.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Plunge router type dremel bit
Image Notes
1. Cutting out the visor opening.
Image Notes
1. Visor had to be trimmed down to fit my helmet. This plastic was very hard to cut.
Image Notes
1. visor in place
2. I shot this extra piece with my upgraded airsoft rifle at point blank. No scratch,
no dent. :)
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Someone else made the visor for me. If you know how to vacuum form, then
you can make your own visor.
Image Notes
1. If there are letters, make sure to reverse the image
Image Notes
1. Printed out on transperency
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. flat white paint
Image Notes
1. The print is under a layer of paint.
Image Notes
1. The other side.
Image Notes
1. Get it at hobby / craft store.
2. Paint is now dry on my graphics
Image Notes
1. Stick onto same side as white paint.
Image Notes
1. Stickers all done.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Cut to size.
Image Notes
1. Sprayed with a light mist of black paint. Before the paint dried I scraped some
off. hard to see but it looks aged and worn.
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Image Notes
1. Helmet on me. Fairly comfortable. But needs better air circulation
Image Notes
1. Foam - Back of head
Image Notes
1. Foam - Top of head
2. Electric fan will go here
Related Instructables
Halo ODST
Armor Build :
Table Of
Contents (TOC)
by vv_767
How
to make foam
Halo armor by
Master-Chief
Halo ODST
Armor: Torso Part 2 of 5 of
ODST Armor
Build by vv_767
Halo ODST
Armor: Arms Part 3 of 5 of
ODST Armor
Build by vv_767
How to use
Pepakura by
TryHonesty14
Using Paper,
Resin, and
Fiberglass to be
the Master
Chief! by
Dr.Professor_Jake_Biggs
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
Comments
20 comments Add Comment
Gunnar120 says:
wimpiam says:
DHeigh says:
vv_767 says:
Caleastro says:
vv_767 says:
odivalq says:
vv_767 says:
illotrevnollid says:
vv_767 says:
Thanks. I will keep that in mind. I may still install a small fan. It gets hot inside the helmet.
MotaBoi says:
vv_767 says:
20 shipping included.
MotaBoi says:
Where from?
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/
vv_767 says:
MotaBoi says:
Alright thanks
MotaBoi says:
vv_767 says:
MotaBoi says:
vv_767 says:
I just added new steps on the torso ible. See steps 8 and 9 .
MotaBoi says:
Nice! It's turning out really good!
http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/