I decided to get my feet wet in my Mando build by taking a shot at building my own helmet. Looking at other scratchbuilds, I originally thought that it would be too much trouble and/or hassle...but when my budgetary proposal was shot down by the boss, I realized that it might be awhile before funds would be available, so what the hell!
I downloaded the templates, bought a couple of posterboards, sat down, scissors in hand, and started cutting. Once everything was laid out, I started with the cap, since that would be the most challenging (in my opinion) part of the build.
I was pleasantly surprised to have this after a couple of hours:
The fit was pretty good on my odd-shaped melon, so i taped up the rest of it & headed to the garage with the hot glue gun. Going off the scratch build tutorial in the archves, I glued down all the seams, inside and out, to give the dome some strength. Once it set, I started attaching the back and visor to the cap. I reinforced the seams around where the visor would be cut out with cardboard, but upon gluing they didn't really want to stay flush/rounded, so I grabbed a couple of my rare earth magnets to hold down the middle & corners better. Here's the result:
Cost to me so far: about a dollar for posterboard and ~4 hours of labor...which I probably would have spent farking off on the computer anyways.
Here's the problem I am now faced with. While there is plenty of room inside the helmet right now, when I put it on the bottom of the front of the visor is about parallel with my chin. If I fiberglass inside and/or add any padding whatsoever, my face will be partially exposed. My first thought is to just add about 1" more around the bottom, but that would probably lead to some challenges extending the 'cheeks' - those have not been glued in yet.
Any thoughts or suggestions are most welcome - this has actually be kind of fun to do! When I am out & about today I'll see about getting the needed components to start the fiberglass part of the build...after I find a solution to my 'short' helmet