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 Post subject: Re: Helmet build
PostPosted: Fri Dec 13, 2013 2:26 am 
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Location: Perth, Australia
plummet wrote:
TheJoe wrote:





Plummet, that's a bit harsh, seabreze style :(


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 Post subject: Re: Helmet build
PostPosted: Mon Jun 09, 2014 11:23 am 
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Location: Perth, Australia
Getting back to helmet:)

This time I'll test my new mold first with just 2 layers of FG. If the size is ok, might slap a carbon or kevlar layer or both:)

Covered the plaster mold with a silicone swimming hat hoping epoxy won't stick to it:

Attachment:
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DSC01193 (Small).JPG [ 70.89 KIB | Viewed 598 times ]


To cut a FG you'll need to place it on top and get rid of excess:

Attachment:
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DSC01194 (Small).JPG [ 92.57 KIB | Viewed 598 times ]


This is how I do it, I draw the line with a pencil and cut it latter (this is marked wrong tho:)

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DSC01197 (Small).JPG [ 145.63 KIB | Viewed 598 times ]


Wet the mold slightly and place a FG at 45/45 degrees, than the second one at 0/90.

Attachment:
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DSC01198 (Small).JPG [ 65.74 KIB | Viewed 598 times ]


There it is:) 1hr job and one nicely saturated fiberglass with slow epoxy (30ml).


No vacuum or anything for now. No wrinkles as well. However the carbon finish we will need to tweak to get no wrinkles at all...


Attachment:
DSC01199 (Small).JPG
DSC01199 (Small).JPG [ 86.26 KIB | Viewed 598 times ]


Enjoj...


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 Post subject: Re: Helmet build
PostPosted: Tue Jun 10, 2014 1:04 pm 
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Taking it off the mold went well!
Very smooth surface inside the helmet. Might actually make a female mold from this:)

I just tensioned a silicone hat all around and than puled it off. The FG I've cut but left a tiny sharp piece which went through the swimming hat:( ah, well... Need to cut it better next time while still wet!

Attachment:
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DSC01202 (Small).JPG [ 80.34 KIB | Viewed 521 times ]


It is way more flexible than a first one I've built with a carbon-kevlar and 2x650g triax fg:

Attachment:
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DSC01207 (Small).JPG [ 59.79 KIB | Viewed 521 times ]


Adding a 5mm "crushing" closed cell foam to check the sizing around my head:

Attachment:
DSC01208 (Small).JPG
DSC01208 (Small).JPG [ 100.13 KIB | Viewed 521 times ]


Not bad size though. I'm thinking would be cool to put the silicone hat on top of FG to get the nice finish:) Will see what to do next.


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 Post subject: Re: Helmet build
PostPosted: Fri Jun 13, 2014 10:11 am 
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And carbon-kevlar goes on top of FG! Happy times!

This is the back side. No wrinkles, as said, work this fabric out! No channels this time:

Image

Gath style, more open forehead:

Image

Might cut it tomorrow...


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 Post subject: Re: Helmet build
PostPosted: Fri Jun 13, 2014 9:13 pm 
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Very Nice!!!! It's good to see you work though the difficulties of this project and come out with a good end result. Looking forward to seeing it completed.


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 Post subject: Re: Helmet build
PostPosted: Fri Jun 20, 2014 6:46 am 
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Cheers mate! Thanks everyone for chipping in as well:)

Almost there! And man, 100 grams that one ! That is with the foam inside before accessories !

Varnishing 2nd layer, 1 or 2 left!:

Image


Follow me @ http://www.facebook.com/ShinaiBoards


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 Post subject: Re: Helmet build
PostPosted: Sun Jun 22, 2014 3:23 pm 
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The time has come to finish this project!

The aim was to build a decent helmet, with easy found materials, and no vacuuming technique, yet light and strong for my application.

Hope you like it!

Many varnish layers with a brush, still not 100% happy, but not bad:

Image

Image

Image

Image

Front side with open forehead for some front neoprene added latter:

Image

Inside 5mm closed cell "crushing" foam, adding standard helmet lining latter:

Image

127 grams weight after added rubber all around, not fully glued yet:

Image

Next thing? Some straps, buckling and that's it!

As always, follow me @http://www.facebook.com/ShinaiBoards


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 Post subject: Re: Helmet build
PostPosted: Sun Jun 22, 2014 8:05 pm 
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Location: The Naki
The big question. Will it protect your head?. Are you going to do any form of impact testing?.


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 Post subject: Re: Helmet build
PostPosted: Mon Jun 23, 2014 3:34 am 
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Thanks for the question.

Any suggestion for testing? I would need to build another one obviously:)


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 Post subject: Re: Helmet build
PostPosted: Mon Jun 23, 2014 4:56 am 
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not sure man.

Here's one for bike helmets.

Is it just one layer of carbon/kevlar? My gut tells me your'd need at least 2.


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