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It was the first time the team tried to build a master completely of sculpted and sanded bondo. Bondo is a really good material to work with, but sometimes a little slow to achieve the desired geometry and finish. Everything starts by designing the 3D model. The tricky thing here is to build the model at the right scale, otherwise the helmet wont fit or it will look like a bubble-head. For solving that problem we built a paper version of our helmet. Three different versions were built until getting the right scale.


Once we got the paper version with the right scale, we covered it with a thin coat of bondo. This way the helmet will be strong enough for a one-usage mold of plaster of paris. Making this mold, we will be able to get a full bondo copy of the prototype built in paper. A good point to start sculpting the real thing.