Here's the first cast once I'd pulled it from the mold:Ĭlearly it needs some padding to keep it up where it belongs.

Then I reassembled the mold parts and made a quick rotocast copy of the helmet: I used that time to clean up 'Isaac' the sculpting armature and make him ready for the next project: Then I left the jacket inside-out to let it air out for a while: Naturally the sculpt did not survive this process. Then peeled the rubber jacket off of the original sculpt: Today I pried the two halves of the helmet mothermold apart: I'm also planning on vacforming the bulk of the other parts of the costume with resin cast detail parts as needed. This way the helmet can be smaller and more form-fitting while still making it possible to get your head in and out. The plan is to rotocast the dome and cast the faceplate separately. I've still got a bit of tweaking left to do, but then it'll be time to mold this guy. I also continued to refine the details at the back of the helmet: In order to make it shiny and smooth, I went ahead and sprayed it with gloss pink: I also used a bit of bondo here and there to fill in some spots and smooth things out. The whole thing was formed with two layers of 1/8' styrene for a base, then a variety of details cut from thinner sheet stock. Using the card stock as a template, I formed the faceplate by heating up some thick styrene sheet and forming them over the side of a bucket to get a uniform curve. Once I had roughed out a few of the general shapes, I cut some card stock to give me an idea of how to form up the faceplate: Over the top of the helmet I started sculpting the separate panels in clay: Then I stuck it on top of a sculpting armature: With the padding removed, there's lots of room inside. In order to make sure I had a good dome shape to start with, I stripped the padding out of a child-sized, open-faced motorcycle helmet. I started this project a couple of months ago and now I'm finally at a point where I'm willing to post pictures of it.

Dead space engineer helmet