Create a Daft Punk helmet!

This is my first post, I will show you how I created a Daft Punk helmet guy manuel! I started this project in 07/12/2010 and 22/12/2011 I finished ... approximately one year of work.
For any questions I'm here;) well tell me what you think, I hope you like it!

P. S. Before I begin to thank Harrison KRIX (Volpin props), for conveying to me that passion! :)

                                                                                             

                                                                           1 YEARS OF WORK IN 4 MINUTES!

the view is not the greatest but it works well

basic form finished

 polyurethane foam

polyurethane foam takes shape!

polyurethane foam covered with dass

 

cut the "ears" :)

 filler metal to fill the imperfections

 the second of 15 coats of filler metal   o.O

finally almost all smooth

thin layer of filler spray to highlight the imperfections

some imperfections

last coat of filler spray to check if everything is ok

design of the shares of the "ears"

 creation of the program for the numerical control milling machine

numerical control milling machine

This is the result of the program ... good!

"ears"

polyurethane foam for sostenerele "ears"

diagram of the "upper" parts

Styrofoam cut as the previous design

I covered the foam with the dass

to improve the surface I used the filler metal

scratched with fine glasspaper

last coat with filler spray

I closed the holes around the "ears" always with the filler metal

I carved a small groove around the "ears"

Another bit of filler metal :)

another small incision

another small incision

these are the two "ears" assembled!

this is the result of all the filler ;)

this is the result of all the filler ;)

preparing the basis for a better grip of the filler

filler metal applied

smoothing of the entire surface with abrasive paper with water

first coat of silicone molds

5 coat of silicone molds with dass

final coat of fiberglass

I poured the plastic resin in silicone molds

finally the real helmet!

shape of the visor

polycarbonate hot-pressed to take the form

visor obscured :)

parts to eliminate

milling to finish the job

holes for the leds

Fortunately, the visor is perfect!
 creation of the base for the lights

ok! perfect .. the visor does not touch the base for the lights
 white paint to increase the reflection of light

 main electronic circuit

 immersion in acid to remove the excess copper and create the tracks!

 here are the tracks :)

 a small "touch of class" :)  Thank you my friend Acromangelo for design the electronics circuit

 polished and ready for welding of the components

 finished!

 Welds are ook!

Acroma at work to program the pic

 suits led strips positioned in segments

 electronic circuits of the "ears" and the lower part of the segments

a hell of wires! : D

creation of the cage of colored squares

Finished!

vernicie fixative for gold plating

design of "cardiogram" :)

result... perfect!

 

test size, fortunately all the measures are good

and finally after 1 month of waiting here is the chrome helmet! is really nice!

I put the sponge on the back to support the colored wires

and here is the result

design of the battery box

PVC transparent to be cut, paste and paint

box with inside rechargeable lithium battery and switch ready!

sponge to help spread the light

test lights! everything works great!

another hell of wires! it was really complicated to fix them all inside the mask!

inner shell with foam to improve comfort

and here "ear" complete

"cardiogram" Oook!

 daft punk guy manuel helmet ready!

daft punk guy manuel helmet ready!

daft punk guy manuel helmet ready!

and this is the end result ... What do you think? it took me 1 year of work but I'm really pleased! :D

thanks for following me! see soon :)