Helghast Capture Trooper helmet build

PreacherMan

PreacherMan

New Member
Dec 13, 2012
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Hey all,
First attempt at making a helmet or a larger pep build, all my stuff has been EVA so far.
Didn't want to freehand it, so the original base was a model made by A1TD/Pepmaster. However, I realized after running out of rondo and having the thing fall apart, I built half of it from scratch by using parts from around my house into the same general shape (namely, acrylic sheeting, camera bits, etc. A LOT of acrylic.)

Here's the build chronologically- the armour comes next. Thinking of making a second one somewhat like this into an Elite Helghast, just started making the mask from acryl today.

Pep-
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Mud coat

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Bondo coat

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Had this weird head tilting thing that happened along the way after it got wet, this was fixed later

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Almost done-
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Start of new build-
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Day 1 update on the second mask in the picture-
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Elite shock trooper Helghast mask start
Nose needs to be reshaped, shouldn't be much effort.
Bottom part is part freehand, part modified Capture Trooper pep build by John Wieger. Upper and nose is freehand acrylic sheeting, straps and forehead assembly/base butchered from old respirator. Forehead armour will be built out at some point, lenses replaced with orange, fibreglassing and filters will happen soon
 
Incredible, informative thread you have going here. Thanks, and if you want to get more detailed, please do. This is great stuff. To be honest, this would work on restoring or fixing a lot of things. Excellent! Who wouldn't want to have stuff like that to mess around with. :)
 
Hi this could be fun..
I always wanted to build my own suit..
did some investigations about it with my friend google. :-)

And i like the EVA-foam version of pep-suits . it LOOKS easy

What you do makes better details i think..
But doesnt the pep-mask collaps when you give it that paint-job?

This will make a great tutorial...:-)
and i like the pictures
 
Thanks!
There's a good amount of tutorials- I can answer as many questions as I can, but this is basically a bible and can explain it way better than I ever could.

http://www.instructables.com/id/Halo-ODST-Armor-Helmet-Part-1-of-6-of-ODST-Armo/

tl;dr it was entirely paper, but it was painted with fibreglass. After the fibreglass cured it was rigid, it was then filled with a mix of bondo and fibreglass which was slushed about, which gave it strength.
After that cured, it was covered with bondo auto-body filler, which was sanded down smooth (some dents and bumps left for that 'worn' look). After the bondo coat, it's rock hard- I've dropped it a few times during early morning building and it's quite rigid. Wouldn't go skydiving with it or anything, but it's solid as hell.

Warning to all, if you don't know already, fibreglass/bondo is toxic as hell and smells like death. I recommend it only if you have an open area to work, and a respirator that's rated to organic vapours of some sort. I used a cheap dust mask that is meant for fibreglass work in an open garage.

Fully pepped suits look amazing but they're SUCH hard work.. Can't say I recommend it without a few months of spare time. :)
 
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The technique my friend and I are using is called 'slush casting', it's essentially taking a 1:1 (or other based on your desired consistency) mix of bondo autobody filler and fibreglass resin, with a bit of poured in hardener. You are left with a goop with a consistency like runny pudding, which you pour inside your helmet (really recommend you fibreglass it first, and cover any holes with painters tape from the outside) and slush about until it evenly coats the inside. After a few hours of cure time, you have a layer inside your helmet that's hard as a rock. Few coats of this and you could stand on it.

bondo.jpg

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Are what I used
 
It's expensive, but if you have you ever thought of getting into Pre-peg carbon fiber? It arrives cold, you throw it in the fridge, and when you ready, you apply the resin, it is already doped up with the stuff, so you make a plastic bag and us a refrigerator compressor motor for some vacuum and suck out the and and the makes sure the resin gets everywhere it needs too. There's a baking process tossed in there, very low temperature, a home oven will do. I have relatives who work in composites and that about all I can say about that. You end up with an extremely, much stronger than fiberglass, solution. :)

Here's a interesting video on the process:

[YOUTUBE]9_tDQTgdsCg[/YOUTUBE]
 
That's beautiful! I love the texture, especially.
I haven't heard about this but will look into it.. shall see if anywhere local has it, there's some industrial sites a bit out of the way that may (my acrylic comes from a plastic depot in a business park).
If this can be done on a small scale with the tools I have on hand, this could be really useful.
Rondo is incredibly strong on its own- (image taken from protagonist4hire and his lovely tutorial)
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Second one is progressing at a snail's pace. Wish I could find my blowtorch so I could heatform this acryl crap properly.
 
I wish I had you for a neighbor, you could help me make a fiberglass nose for my M.G.!! :)
 
MG? Show me what you're thinking of and I can try and think of ideas/help in any way I can from up here. :)
 
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Base coat has been applied, some detailing left to do. Most of the sanding is done, filters are applied. Funny, if the seal is tight enough it can actually be used as a respirator if a filter is put on.
Next up, back of head. Making the top from EVA foam and acryl.


To clarify the second build is supposed to be this-
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Thanks! Here's a just-about-finished helmet.

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Just some spot work left as well as a Stahl Arms decal, and getting some glowing LEDs into the eyes (one way orange reflective lenses right now)
 
You know a country's economy is screwed when they're having hobby forums spammed.
I used to live in Al Ain.. nice place. Not so nice now.
Just sculpted an over head/rear head guard. Pics soon. Thanks all. :)
 
Head piece was too big with the foam blocks in it. Took them out, now it's far more streamlined. Last update for tonight, I promise!
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Time to start working on the armour itself
 
Yep!
Here you go. It was made by John Wieger, he's a pretty nice guy.

Download links are in the comments-

http://jwieger82.deviantart.com/gallery/37465093#/d4sc6t1

Both versions are there, I made Version 2.

Sadly, the Elite Shock Trooper was a one off build from foam and acrylic, not very much pep was involved with that- it was a scratch build. I can do a deconstruction if you'd like.
 
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