Sunday, November 29, 2009

new paper cast made, foaming soon.

due to the amount of school work i have to do, the time i have to work on this project has significantly decreased. weekend are my windows of opportunities for this project and it seems as though im gunna be using the 8 months i have to the fullest. volpin (harrison krix) has been nice enough to sell me copies of his schematics so the project will be that much easier. the hi-res drawings and blueprints will help quite a bit.

Saturday, November 28, 2009


well, i just figured out that i picked up the wrong foam when i bought it and everything that i had done up to this point has been scrapped.. good thing i have 2 paper molds! ill be back up and running in a day or two once i find the right foam to use :/


OK, so now im gunna explain the materials needed and some of the links im using to a certain extent. so, to start off, i went out and bought the following,
sturdy posterboard (1.59c a sheet, 4 sheets lasted us for 2 helmets)
air dry clay ($6 per box, theyre MASSIVE boxes, but if they dont have large boxes, estimate the amount you'll need)

3x expanding foam ($3 a can or so, we bought 2, used both on ONE helmet and went out to buy more, so i suggest 4 cans. EDIT: BUY GREAT STUFF (yes thats the company name) INSULATION FOAM IN A RED CAN)
all purpose BONDO ($11 for a large can. you only need one)
acrylic sheets (around $0.58 per sheet, very small sheets. you dont need much, we bought 4 small sheets just in case)

VHT nightshades ($15 per 10oz can, we onl bought 1 can, but we'll find out how much we need when we get there)
smoothcast and other casting materials (NOW, this set me back a lot. it was $145 for a gallon of the silicone mix and like $84 for the smoothcast resin. smoothcast 300, to be exact. but, sadly, its required for this project. and if you do end up ordering all of this, you only need a 1 gallon jug of silicone mix and 1 gallon jug of smoothcast 300)
OLFA BLADE (this will run you about $2-4 depending on which model you buy. you'll need it to cut the foam. this knife is flawless stainless steel and it cuts the foam like butter. nice and smooth.

those are all of the materials needed to build a helmet from SCRATCH! if our helmets come out well, we will be willing to sell helmets completed, or kits if you want to build them yourselves. depending on the amount of helmets your making, you will need more than just one case of each material. i listed how much we purchased for 2 helmets. hopefully, it will keep us set for the project. but again, if you dont want to build one from scratch we are willing to sell kits and completed helmets.

so i myself am using a couple tutorials and i am following some other forums and what not. here they are if you choose to use them:
VOLPINS GUIDE, this guy is a professional prop builder and a god to most guys like me. im following his guide like a bible. here it is,

im also following a forum in which someone else is following volpins guide, and is doing exactly what i am. i like to see his progress, for he is much farther than i am. heres his "guide"

theres all the guides and forums im following right now.

heres a little teaser for where i am at the moment. this is actually from yesterday's foaming. i just applied the second layer and its looking good. that large hole in the middle isnt supposed to be there. the foam collapsed because i didnt have any paper there.

got lotsa work to do today.

ok, so ill be posting all of the materials and how to stuff you need in my next post, but for now, i have to do some work. D.A.F.T. will be in session later in the day. my next step is to cover the helmet in another layer of foam and begin carving the shape.

Friday, November 27, 2009

commencing Project D.A.F.T. as of today!

so today, my friend and i bought all of our materials(well, most at least), sat down and sorted the whole project out. were estimating a couple months till completion time considering the amount of time we have to work on the helmets, but we did squeeze in a few hours today to get the poster board molds done and spray them in expanding foam. all of the materials used and the rough tutorial for this project will be listed in another post soon. links to everything will also be listed as we continue in our journey to create this work of art.