My best friend is a wiz with pepakura and put together this pep model of a bio helmet for me
I made some temporary cardboard braces on the inside to make sure it held its shape while I applied a few coats of resin on the outside
Then I took the braces out and lined the inside with fiberglass mat, I added an extra layer in the cheekbone area behind the eyes where i felt it needed reinforcement and dabbled in a generous layer of resin to the fiberglass on the inside, this made it REALLY strong, I even banged it on a table to demonstrate to a co-worker how durable it is now!
After that I Marked as many high and low areas with a marker that I could to make applying the bondo easier. It really didn't take that much bondo to smooth it out due to preparation and the excellent pepakura work of my friend.
Here I am getting the shape pretty good, I gave it a coat of primer and made some final shaping adjustments, the onlt trouble I had was with the crown ridge area. I tried not to make it too perfect and smooth because it is supposed to look like a forged metal mask.
Final coat of primer before finsh sanding with a fine grit foam sanding block
Starting to look better ! I coated the whole mask in a clear coat to preserve the weathering, give it a little shine, and improve durability.
I cut a strip of Sintra and made it so it attached to the bio mask and wrapped around the back of my head, kinda making the mask into a helmet, also giving me a place to attach the dreads. I cut the end of the dreads at a 45 drgree angle and hot glued them making a row just under the crown edge, and another row under that, the hot glue actually holds it really well.
I took apart a 3 led headlamp I got from Lowe's on sale and installed the guts into the laser housing, They look blue here as I haven't yet tinted them red. For now, the "beads" are just chrome tape until I decide to fabricate some better ones.
Sport hunter vs. Bounty hunter, that would be epic !