In Part 2 I fiberglassed the inside of the paper helmet to add strength. The next stage is laborious but also quite rewarding. In order to get the smooth shapes of the real helmet I used U-Pol P38 Car Body Filler (similar to Bondo in the States). The process is sand – fill – repeat. I have lost track of how many times I have done this. I started with the main dome then moved to the visor. I found that a foam sanding block works best.
Tips for using filler would be:
- Use a respirator and gloves
- Use a clean mixing surface and spatula each time
- Thin SMOOTH coats are best
- Always use at least some hardener.
- Use coats of primer paint to pick out lumps and holes.
The key with this process is patience. There were times where I thought it was useless and I had ruined it. Just keep sanding and filling. Eventually it comes back to you and it is very satisfying. This process can go on for as long as you want – depending on how much of a perfectionist you are. Remeber when chrome paint is applied any lumps or bumps will be magnified so it is worth putting in the time now to get it perfect. The following photos show around a months worth of progress.
Still a long way to go but it is slowly coming together.