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Helmet build

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downunder
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Re: Helmet build

Postby downunder » Fri Dec 19, 2014 6:37 am

Varnished!

The 'skin' is now ready for shaping and cutting and will weight even less.

Ultra shine carbon is a pleasure for eyes :)
DSC02186 (Small).JPG
DSC02187 (Small).JPG
DSC02188 (Small).JPG
Light as feather, strong as, well, a Carbon fiber:) This is 200g carbon + 2x200g FG.

If you like what you see I'm taking orders :) :)

Enjoy

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Re: Helmet build

Postby downunder » Wed Jan 21, 2015 4:05 am

Hey,

I know it's not everyones cup of tea but why not give it a go?!
DSC02408 (Small).JPG
I hate to see this shiny surface sanded off completely but that is the necessity before spraying a varnish...A few coats will do.
DSC02410 (Small).JPG
Shoot any questions about the construction!

Enyoj

PS

All this 3D surface build is just training for the Mother of All Builds. Hopefully soon!

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Re: Helmet build

Postby windrupted » Sat Jan 24, 2015 5:40 pm

downunder wrote:Hey,

I know it's not everyones cup of tea but why not give it a go?.........

Shoot any questions about the construction!

Enyoj

PS

All this 3D surface build is just training for the Mother of All Builds. Hopefully soon!
"Just finished a plaster mold head (close:). Than I'll use a hot vinyl to wrap the mold and seal it. "

The molding: how do you do that? I have seen foam imprint kits for making foot orthotics that would work pretty good, but have no idea where to obtain them. It's cardboard box with foam in it (resembles PU surfboard foam but reddish in color and very light density). It's very light, so you could send the box out to your client and have him or her make the mold then post it back, similar to the way that Engine does their custom harnesses.

Great layup.

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downunder
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Re: Helmet build

Postby downunder » Sun Jan 25, 2015 3:25 am

Hi

thanks for your question. For me, the easiest method for making the mold is using an old helmet (skate, etc). It's got only a few holes and after removing a lining, the volume is slightly bigger.

Seal the holes, put some plastic bag or a kitchen wrap in it and pour the plaster. After cured this is your mold. Some sanding AND more volume is needed.

I think it might be possible to use a spray foam (or 2 part PU foam), in a similar way instead of plaster.

The plaster mold is heavy tho, very good for laying up. Light mold would bounce all around.

I am using a silicone swimming hat to seal the plaster before the layup (vinyl wasn't working).

The swimming hat's might also be used to accommodate a volume or size. Wrap a mold in 10 rubber hat's and hence the bigger size :)

How bigger one needs depends on a foam used for protection inside a new helmet. I'm using 5mm foam. My skate helmet was too big for me, but this was perfect in the end because it can accommodate this 5mm bigger volume.

I did look at commercial molds but couldn't find any. There are some modelling styrofoam molds on e b a y but can't find the right sizes. Good tip thanks.

Even if a skin helmet is slightly bigger (I am 59-63cm helmet size), one can always use a ticker foam for a smaller head, resulting in a better protection as well.


Enjoy

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Re: Helmet build

Postby downunder » Sat Feb 14, 2015 3:29 pm

How's this? :)
DSC_0118 (Small).JPG
DSC_0118 (Small).JPG (87.71 KiB) Viewed 1610 times
DSC_0116_re.jpg
Padding? Hm...

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Re: Helmet build

Postby downunder » Mon Jun 08, 2015 10:09 am

Hi all,

for anyone interested in a helmet making process, this is the link to Nolan:

http://www.webbikeworld.com/eicma-2010/nolan-helmets/

Quite interesting water based varnish.

D.


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