Daft Punk Thomas Helmet Phase 2

The mould for the Thomas helmet was made using Smooth-ons Rebound 25, before starting I mixed a small batch of the silicone and poured it into an egg holder.

I'll use these as mould keys to help the silicone mould lock into the fibreglass mother mould that will support the silicone mould. I was that busy making the mould that I forgot to take in progress pics but here's two of the finished mould inside and out :

To go into more detail of the process I basically brushed on a normal coat of mixed silicone as a detail coat to get into all the nooks and crannies, after that I waited for the silicone to become tacky and ready for the next layer. I added another layer that had been thickened with a thixotropic again from Smooth-on, I did this repeatedly until I had a good thickness to the mould which took around 5 coats. Two layers of fibreglass (the mother mould) were added to each side and bolted together to keep the rubber in place, this is where the mould keys I showed earlier come into play.

To mould the ear pod I built a mould box using lego bricks since I had them handy and they're easy to build different shapes rather than having to cut different shapes out of MDF or something; plus legos more fun !

Nice thick solid walls so there's no need for a support shell.

I cast a helmet in fibreglass, fibreglass holds the detail well and is also extremely light but strong, which is the right combo for something that's going to be worn for a length of time at a convention :D

I circled a few low spots where the cast needed a thin layer of filler to get the surface as perfect as I could. 

I then trimmed out the visor material and left a lip to attach the new transparent visor to. I then primed and wet-sanded the helmet with 1500 grit sandpaper and padded the helmet for a snug fit so there's no wobbly bobble head action when being worn.