DIY Protoman Helmets

How I build Protoman Helmets

Abstract: Create Protoman Cosplay from Cheap Motorcycle Helmets

Status: Complete (This article is WIP)
Video: https://www.youtube.com/watch?v=8YA-5JL1a94

Surprise! 4 years in the making, I'm finally sitting down to type this out and provide video and photos all in one place. It's a work-in-progress, so please give feedback.

HOLY SHIT

 I haven't updated this blog in over a year. Hello.

The website was Half-Life 3'd into development hell by yours truly. I am restarting on the resources for it and hopefully it'll be done in 8-10 years.

In the mean time, I have actually been saving up a lot of content and projects to show you all, including more Protoman cosplay related shit, because about 7 thousand people have checked on that section of the site in the past year. Which is a lot for some dick in his bedroom.

The Youtube page is live! The channel name is indeed DestructoBlog.
This is now my primary youtube account. The other one wasn't deactivated because I think I lost those videos...so I just burned my password and left everything the way it was so all the old videos are still live (and they should still be usable in this blog).

Oh by the way, here's the link http://www.youtube.com/destructoblog

So, at your mercy I will be trying to produce a video every 1-2 weeks, eventually getting down to 1 major upload and 1-2 little snippets per week. The website will still have other things on it but for the time being I'm going to focus on the youtube and the video making, because that is what I'm really passionate about, and it's also the thing I know the least about. That makes sense, right? No? Fuck.

I'm not dead/Death-Eater/Jurassic Park Claw

Hello, been super busy with classes and whatnots so I haven't had a lot of time to keep the blog up and continue to force eyeballs over to it. I've still got some irons in the fire for newer, bigger projects, and I'll eventually get some real-life DIY how-to shit on here soon, just haven't had the time or the drive to do so. Anyway.

For Halloween, I finally got a cast cut and painted for Caci's death-eater costume. Her roomie Regan was going as Dr. Grant from Jurassic Park.

Finished Master Sculp. All molds will be made from this sculpt.

Closeup. The entire mandible/cheek area was redone in fiberglass filler.

This is my quick cast off of the mold.  The mold broke twice, I shouldn't have used plaster molds...hard object inside of hard mold = you have to break the mold off with a hammer. Anyway, it damaged the mask and I had to throw the whole thing together in a few hours so the finished product isn't quite as great as it should be.

On to the raptor claw...

Found pics online, made a mock up out of cardboard from a Cheerios box

Molded modeling clay on top of the cardboard, carved out appropriate doodads

Plaster mold made on top, then carved out this side

Empty mold. I keyed it on both sides then poured a combo of resin/filler.

Primer, paint, then more paint, then strategically sanded to look old.

Texture!

 

Protoman Requests/Responsies/Ego Stroking

Hello internets. It's been quite a while since I've posted on here (the death-eater mask keeps getting pushed back because of things like Arkham City) and I thought I should post a few things that people have been asking me about.  Protoman related. Blah, blah, shit. Anyway.

1. Yes, I will build you a Protoman/Megaman/whatever helmet to your specifications. It'll probably cost you around $100 dollars, it's hard to say exactly how much because it'll be commission work.  Here's what needs to go down, though.  

EDIT:
I don't remove posts, I just edit them. I will no longer be taking helmet requests. They take to goddamn long to make and it's bullshit to make people wait to song for something. Sorry. But I will list the materials list here up and I will still answer any questions you have with my best braincells.

•   This first part is on you.  Figure out your helmet size.  If you just pick a helmet that may or may not fit, we would have just wasted a lot of money and time.
•   Ship me your helmet. I'd rather not go out and buy one and have you not pay me, or have to postpone the project and I'm left here with materials I can't use. If you get your fitment done and you find one online that you like, paypal me the money and the link for it and I'll buy it and just ship it here myself.
•   Pay me and I will work for you.  I have PayPal.  Every time I work on your helmet I will send you photos to prove to you I'm doing the work. I don't want a bad reputation, but I don't want to do work for no money either.  If you prefer to pay me a chunk of money straight up that's fine.  I'll be sending you a statement detailing exactly what I did and how many hours each step took to verify that I'm not just taking your money.
•   Pay me for materials.  I keep very good records for projects like this. I will scan receipts for you and package them in .pdf or a folder of .jpgs for you to prove to you what I'm buying.  I want everything to be completely transparent.
•   Cancellations.  If at any time you decide you don't want the helmet any more, I will request payment for the materials I've used and work I've done to even us out.  If you want your incomplete helmet back, and you've paid me up for the work I've done, I'll send it back to you.
•   Finishing the project.  I will only ship you your helmet once you have paid for everything. Projects like this take a lot of time and effort to complete, I just want to make sure I'm getting paid. When I ship you your final helmet I'll have it weighed and you can paypal me for the shipping costs.  It will most likely be packed pretty tightly and will include documents of the receipts and the full work statement included. 
•   Tell your nerdy friends.  I do enjoy having projects out there for people to see. I love having my own little blog things like this, and I intend to update it as often as I can.  Referring me to your friends will keep projects like this alive.  With your permission, I'd also like to write up a work log for the blog to show everyone else what you've ordered.
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  2. Materials.  You've seen pictures of them, but I guess I've never gotten around to posting exactly what I bought. Here's an approximate list of the stuff that went into this helmet. Ignore the red text.  Well, ignore the fact it's red. Not the words.

• Helmet (derp)
• PVC ear piece (custom cut and shaped): X2
• Plastic Drain Insert (inner ear piece): X2
• Craft wood (green inserts, cut into circles)
• Double Sided Outdoor 3M tape: 1 roll
• Hot Glue: -donated-
• 18/20 ga. wire: -donated-
• On/Off switch: x1
• 9v power connector: x1 (comes in a pack of three)
• 9v battery: x1 (can buy your own, I guess)
• Small Wonderflex Sheet (21"x13"): x1 <----this is if you want the white head piece mounted to the visor as a separate piece, and it is used to make the battery compartment
• Foam Weatherstripping: x1 Roll -donated-
• Foam Padding: -donated-
• Short Strand Fiberglass Filler: -donated-
• High-Build Automotive Primer: x1 can
• Enamel Red Spray Paint: x1 can
• Krylon Flat White: x2 cans
• Lacquer Clear Coat: x1 can
• Glass Tinting: x1 Can <---Stuffs 16 dollars. If you use the stock shield on a helmet it will be clear--so we tinted Jay's. Some people use over-sized glasses; you pick.
• 400/800/1200 grit sandpaper: -most likely donated-
• Hyper Bright Green LEDs: x8 or x10
• Pack of Resistors: x1 pack (may have some left over but I'm not sure, only need 8 or 10)
• 5v Regulator: x1
• Mini Blank Circuit Board: x1 (may still have one of these too, if not they sell them at Radioshack)
• Extraneous Dremel bits that may explode during use (cutter wheels literally explode when they overheat)
• Black cloth to cover up wires/battery cover/whatever. You don't need this, but you may want it.
• Arduino programmable board
• Condenser Microphone
• RadioShack mini-amp
• Male-male audio cable

Anyway here's the two most asked questions about the project. Feel free to comment, I always hop on here and answer.

Death Eater Mask 2/Randomness

Hello, it's been a bit since I've posted in here, but I've been busy.
Firstly, I have made my first cast of the death eater mask already, and its been sitting around for a while getting worked on when I get time. Secondly, I'm devoting my money to buying useless collectible figures (DAMN YOU METAL GEAR PEACE WALKER SQUARE ENIX KAI FIGURES).

I'm also trying to secure one of those awesome FOXHOUND coats for Halloween from abbyshot.com, but the funds are low and so is morale. All of this, if it happens, will end up on here in some fashion. Also, I've been looking online for Metal Gear figures/statues/models for while, and apparently this year is the first time they've ever made them commercially available. This lead me to some geniuses who made some accurate LEGO Metal Gears, and led me to make my own TX-55 out of lego.

So it's been Metal Geary. Eh.
...

Anyway, the death-eater update.

No pic of the mold itself, but this is the glassed in mask in the mold

The mask being pulled out of the mold

After it was cut and sanded, the bottom left of the cheek is indented because theres nothing there. The mold broke as I was glassing.

I filled the broken part up there by the chin with filler

 

Pic of the mouth cut out. The line wasn't a part of the original drawing, but it was impossible with the tools I have to cut little notches in each section, so I just cut a line there.

And I even have pics of the Lego TX-55 AKA "YellowToe":

Removable nuclear warheads from the missile pak

The warheads

What's up.

comparo of the lego and the spec drawing (i drew a smiley face on it)

Ballin. Looks a bit like the MadCat from mechwarrior here

That's all the nerdy shit I got for you today. Be sure to subscribe because I'll be stepping up the posts here soon again.

Death Eater Mask 1

Yo. Got half of my supplies, so I was able to create the mask design with clay over a mask. I got it about where I wanted and sprayed it with clear. Here's some results.

Brushes, 2 packs of clay, mask, plaster of paris, ceramic carving tools, and a custom stencil I made in Illustrator.

Theres the clay. Its really hard to use. Found in hobby lobby.

I'M KILLER CROC

Sorry I just thought that looked cool.

Bit of a shitty pic. Sculpted. Wanted to do more with the designs in this stage but I ran outta damn clay.

Putting the mask in plaster as I type this. Update tomorrow or Sunday.

I'll just leave this here.

Shhh, secret blueprints.

Hybrid of the Bellatrix mask and another mask.

Saw the last episode of IndyMogul's BFX where they made a fiberglass death eater mask from Harry Potter. I decided I could easily do that.

So, my girlfriend couldn't decide what to wear on Halloween and I spotted this and I was like all looking for something to do Halloween wise and like you know like so there.

Wooorst post ever.

Stay tuned for super awesome updates in the coming weeks on that, I promise to have a halfass full build up for it on here as I create it and no more awful posts like this one you're reading.

In other Halloween news, I have decided to become one of two things:

Big Boss (Young Boss with old outfit, probably, cause its cooler)

Psycho Mantis w/Coat (May buy a mask or make one OR buy one and customize it oh yeah +1 me good job good job roflol)

 Anyway since this is the worst post ever it might as well be a short one. If anyone would like to comment on these new project ideas feel free or FUCK OFF.

JK it's statistically unlikely you will comment.

Stay tuned as always.
-K