My son's halloween costume
 

Now that my armor is done, I have used halloween as an excuse to make luke his. He picked a mandalorian armor as his kit. So i got started.

Been working on the helmet for the last month or so. Started using a pepakura file. I used cardstock as my medium, cut it and glued it together.

http://i307.photobucket.com/albums/n...psxzgd3bhb.jpg

After I got it where i wanted it, I put resin on the outside and fiberglassed the inside.

http://i307.photobucket.com/albums/n...psnilnjtqh.jpg

Once that dried, I bondo'd the outside and sanded it smooth.

http://i307.photobucket.com/albums/n...psrqccy95g.jpg
http://i307.photobucket.com/albums/n...pso1ulla0i.jpg

Re: My son's halloween costume
 

once that was done, I put a coat of primer on it just to make it look better

http://i307.photobucket.com/albums/n...psife0d95i.jpg

Then it was time to make the mold. I went the cheaper route and just used silicone from Home depot.

http://i307.photobucket.com/albums/n...psmgp5huyc.jpg

Then it was time for the mother shell. Made from fiber glass.

http://i307.photobucket.com/albums/n...psiytxb1yh.jpg
http://i307.photobucket.com/albums/n...psih4eqspe.jpg
http://i307.photobucket.com/albums/n...psxjk1dnzt.jpg

Re: My son's halloween costume
 

when the mothershell dried, it was time to remove the pep helmet

http://i307.photobucket.com/albums/n...psjbr02ecn.jpg

Then I started slush casting helmets from it.

http://i307.photobucket.com/albums/n...ps0cooicet.jpg
http://i307.photobucket.com/albums/n...psd1zywfh2.jpg
http://i307.photobucket.com/albums/n...psbpj3alco.jpg

Re: My son's halloween costume
 

so now i get to do some sanding, painting and such. can't wait.

here's the Orioles themed paint scheme we are going with.

http://i307.photobucket.com/albums/n...psjflg4bux.jpg

Re: My son's halloween costume
 

Use the force, Luke

Re: My son's halloween costume
 

Vary cool

Re: My son's halloween costume
 

that's so cool, it's looking great :tu

Re: My son's halloween costume
 

Very cool!

Re: My son's halloween costume
 

thanks

did some sanding clean up last night and cut out the t-visor area. got luke to do a little modeling.

http://i307.photobucket.com/albums/n...psiquolgxb.jpg

went to home depot today and got the paint. going to do an under layer of hammered silver and use the vaseline technique so that you see the metal look under the battle damaged areas of the armor.

http://i307.photobucket.com/albums/n...psi9rixj2o.jpg

Re: My son's halloween costume
 

Little short for a stormtrooper isn't he? :D

Re: My son's halloween costume
 

Holy snikes, count me impressed! Fine job, sir!

Re: My son's halloween costume
 

started painting today. first was the primer and then the hammered silver paint.

http://i307.photobucket.com/albums/n...psbd34pvbr.jpg
http://i307.photobucket.com/albums/n...psgyrocncy.jpg

Re: My son's halloween costume
 

Cool!!

Re: My son's halloween costume
 

Will you be my Dad?http://i156.photobucket.com/albums/t...smiley-004.gif

Re: My son's halloween costume
 

well. after having a heck of time with the first can of orange spray paint that i bought (it was actually stripping the other paint off the helmet when i would spray it on), I was able to get the t-visor area painted with a new can. guess i will be emailing rustoleum about that.

http://i307.photobucket.com/albums/n...psy8ditfex.jpg

also picked this up to go with the costume.

http://i307.photobucket.com/albums/n...psiwvc42ga.jpg

picked up a replacement visor for a motorcycle helmet, marked it and have it ready to cut.

http://i307.photobucket.com/albums/n...psjtqgzcav.jpg

Re: My son's halloween costume
 

Sweet!!!:tu

Re: My son's halloween costume
 

he wanted to try it on. ha

http://i307.photobucket.com/albums/n...pss0ojzfhd.jpg

little wet sanding and clear coat and it will be ready for the visor and padding.

http://i307.photobucket.com/albums/n...psmoeo4a8b.jpg

Re: My son's halloween costume
 

Very nice, I kinda seriously wish I could contract out an unpainted helmet from you. I'm just afraid my big noggin wouldn't fit.

Re: My son's halloween costume
 

Very cool and great work :tu

Re: My son's halloween costume
 

Rob - Now that is a COOL kid! :banger