Samus Helmet Tutorial




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Start off with a full-faced motorcycle helmet.  Find the smallest size you can (this one was a kids XS).  Don’t worry if it doesn’t fit, you’ll be gutting all the insides.

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saw the chin part of the helmet off.  Remove all of the padding and styrofoam on the inside.  Remove all the of the screws on the outside.

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Attach a stencil of Samus’ chin part of the helmet.

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For the earpieces, use a pair of safety muffs.  Gut the padding and remove the head piece.

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It’ll attach to the side of the helmet like above.

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Transpose the chin stencil onto 1/8″ PVC sheet.

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Attach the PVC chin piece to the helmet.  Heat as necessary to get the desired bend.

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Using spackle or bondo, fill in the holes left from the removed screws.  Fill in any gaps between the newly installed chin piece and the helmet.  Using a power sander, sand the ear pieces until they fit flush to the sides of the helmet.

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Above shows bondo being applied (before sanding it smooth).

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Sanding the entire surface of the helmet until it is ALL uniform and smooth.  Rinse out dust and dry with a cloth.  Apply masking tape for the black lines on the helmet.

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Prime the entire helmet.

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Paint the entire helmet.

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Cut a piece of clear acrylic for the visor portion.

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Attach it to the insides of the helmet as shown above.

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Remove the tape and color on the black lines on the helmet.

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Using then vacuum tubing, attach it from the front of the earpieces to the inside of the chin.  Attach a trapezoid shape of PVC to fill in the gap on the chin piece.

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Using a green tinted visor, place on the back of the acrylic.