Making the Rocketeer Helmet - Decor

Hey Gang, I'm back with more pictures of the my Rocketeer Helmet.  

I started by drawing where the vents and the weld lines should go.  

Then I got some air dry clay and molded them in place. I have never worked with this type of clay before, so this will be a learning experience.

Top View

Back View.  Now I just have to wait for 24-48 hours for it to dry.  

Don't know if I can wait that long.

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Making the Rocketeer Helmet- The Fin

Update on the Rocketeer helmet. That I started making here. and then continued here. 

I cut a piece of masonite out in the shape of the fin.  I didn't get it exact as you will see in the later photos.  But it isn't anything that I can't cover with Bondo.

I epoxied the fin onto the helmet.  It only touched in the front on on the back side top of the helm.

As you can see there is a gap in-between the fin and the helmet.

The back doesn't even touch at all.   But this can be fixed.

i forgot to take pictures of the bondo process. I smeared bondo into the crack and once it hardened I sanded it down smooth. Then I added a coat of paint to the new fin and all of the bondo areas.  I cracked the bottom of the helmet in two spots.  One was on the chin, and the other was on the right side.  I saw the one on the chin and fixed it. I only found the one on the right side when I painted it.  But that is where the decorative stuff goes so I am not too worried about it.

I am really excited about the way this is turning out.  For my first attempt at anything like this I am really pleased.  I am not quite sure yet how I am going to get the decorative stuff on the sides or the air vents on the top.  The pepakura file I had didn't have those pieces.  I guess I should have looked at that first.

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Making the Rocketeer Helmet - update

Quick update on the Rocketeer helmet. That I started making here. I have found that there are a lot of people who have either never seen the movie, or don't remember the movie.  So here is the movie poster.

Remember it now?  If not you should rent it and watch it.

Anyway the helmet should look like this.

This is what I have so far.

This is several coats of bondo and or fiberglass resin, and lots and lots of sanding.  I spray painted it grey to see where I needed work.  I might need a few more coats of bondo.

Next coat of bondo and sanding

Because I am a bit over excited to see what it looks like finished I spray painted it antique gold.

Then found a bunch of places that needed to be repaired. So more bondo and more sanding.

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Mission: Impossible?

The Mission:  Turn a giant spool into a stone well stage prop.  

Uses: An actor has to sit on the edge of the well during the performance. 

The Task: Using as little money as possible, and without altering the spool in any way.  No painting, no cutting, or lasting effects.  

Deadline: One day.

Do you accept this challenge?

Yes! 

This is the spool in question.
I started by getting a piece of paper mill paper that was big enough to go around the spool. I found a roll of paper thinner than I am used to at Hobby Lobby for about $4.50. I painted the paper gray (with some paint I had lying around the shop). I don't have a picture because it was threatening to rain and I was trying to hurry.  I hung the paper in my shed to dry.

The spool sits pretty level although it was a bit wobbly.  There are 4 metal rods that run the length of the spool and stick out on either end. I tightened these up and that made the spool a lot more sturdy, but then posed a problem for me.  Now I had four bolts sticking out about 1/4 to 1/2 of an inch out of one end.  Since I wanted to make this as non-wobbly as possible I didn't want to have the bolts on the bottom. If I did, when the actor sat on the side it would slightly tip.  Nope the bolts had to go on the top.  I had planned to cover the entire thing with paper mill paper but with the bolts sticking out of the top I didn't want the actor to sit on them, or the bolts tear through the paper.



The Solution: Styrofoam.  I used a scrap piece that I had laying around the shop and cut a hole in the middle.  Then I cut random shapes only about an inch deep.  This made the look of stones without the individual ones.  Then I took the heat gun and heated up the edges and middles.  This makes styro look more rock-like. For more on how to make rocks visit this.

As you can see it went around the bolts solving my problem.

Next I needed to do the hole in the middle.  Without cutting or painting the spool I cut a piece of paper mill paper in a circle and painted it black (with some paint I had sitting around the shop).

I painted the rock topper with some dark grey paint (I had sitting around the shop). I also thin down the paint a little.  This helps get in the cracks and holes.

I noticed there were already some staples in the spool, so I stapled the black spot (a pirate's death sentence for those of you who are pirate fans) in place. Then I crumpled up the gray painted paper mill paper and opened it back up.  Much the same way I did here.  I unrolled it and stapled it on the top and bottom making sure it had a lot of wrinkles.  After that I got my paint sprayer and sprayed black paint up from the bottom.  If you paint the dark color from the bottom it looks like a shadow.

I put the styro stone top on and held it in place with a few screws.

It is not my best work but considering the
Project Triangle…

I am pleased with the result.  

The Cost:  $4.50 (for the paper.)

Here is a pic of it during the performance.