Noob here. Been lurking for awhile but decided to finally register. Alan's templates are really cool, and I have started working on my own scratch-build.
One thing I noticed is that I discovered I had to enlarge the dome template to 103% in order to get it to match the main helmet part of the template which I had printed out full size.
Anyway, I had been looking around for cardboard or sintra or styrene or something similar. It seems hard to find a piece big enough for the inner and outer shells of the template. So I was in Lowe's the other day, and spied some white 5 gallon paint buckets, and thought it would work as material to make the helmet out of. I was able to cut the dome base out of the bottom of the bucket, after I had cut out the inner shell. I have 2 more buckets to work with, and will cut out the outer shell from it.
Running into minor snags here and there. One is that I guess since the material is thicker, the inner shell did not quite wrap around the dome base, so there is a small gap in the front of the helmet. I figure this is okay since this part will be cut away for the visor anyway. I will be sure to leave enough material to wrap all the way around in the back when I cut the outer shell.
Another issue is finding the right glue that will bind to this stuff. PVC cement doesn't work. I found that if I rough up the plastic, super-glue holds up pretty well, as does hot glue. Anybody have any suggestions for the best adhesive for this kind of material?
One thing I noticed is that I discovered I had to enlarge the dome template to 103% in order to get it to match the main helmet part of the template which I had printed out full size.
Anyway, I had been looking around for cardboard or sintra or styrene or something similar. It seems hard to find a piece big enough for the inner and outer shells of the template. So I was in Lowe's the other day, and spied some white 5 gallon paint buckets, and thought it would work as material to make the helmet out of. I was able to cut the dome base out of the bottom of the bucket, after I had cut out the inner shell. I have 2 more buckets to work with, and will cut out the outer shell from it.
Running into minor snags here and there. One is that I guess since the material is thicker, the inner shell did not quite wrap around the dome base, so there is a small gap in the front of the helmet. I figure this is okay since this part will be cut away for the visor anyway. I will be sure to leave enough material to wrap all the way around in the back when I cut the outer shell.
Another issue is finding the right glue that will bind to this stuff. PVC cement doesn't work. I found that if I rough up the plastic, super-glue holds up pretty well, as does hot glue. Anybody have any suggestions for the best adhesive for this kind of material?
) and single layer mat board, and it's not too bad on the wallet. I bought three sheets just in case I make a booboo ( i did 
), and also so I can scratchbuild the knees, gauntlets, and part of the rocket pack with it.
. Hey WOF, any chance we will ever get templates for making a working firespray? :confused I'd love to fly around in my working copy of "Slave-1"!
