Version 2 of this project focused on taking the original helmet Level 3 helmet design and making multiple copies for Xbox Canada for Toronto Fan Expo 2018. When I got asked to make 3 more helmets for the Xbox booth, I knew I needed the previous completed helmet to get a head start on my deadline.
I received the helmet with minor damage that I fixed with Bondo auto body filler and spot putty, Free Form Air and molding putty. Once the helmet was all patched up, I sprayed it with some spray filler to get minor imperfections and scratches out. Once that dried, I hit it with some gloss clear coat to make sure I get smooth casts from my molds.
The first step in the molding process was the face plate. I placed the piece on a piece of glass to get a cleaner seem and edge while also giving me a view on the inside. I lined the empty spaces with cardboard and oil based clay to prevent silicone from spewing into the inside.
After I sprayed the piece and walls with Ease Release (a spray on lubricant/Vaseline), I applied some Smooth On Rebound 25 silicone rubber in thin layers until I had a thick enough coat to start mixing in the thickener to get an even thicker coat while allowing the silicone to set in place while it dried. After letting the silicone completely dry, I built some MDF wooden walls, secured with hot glue and duct tape. I mixed and poured a rigid foam to act as my mother shell to keep the silicone in place while I poured material in the mold.
I used a slush cast method to getting the copies of the face plate using a semi-rigid casting resin from Smooth On. A similar method was used for the base of the helmet while only changing the orientation and using plaster bandage in a 2 part method. The same resin was used for the base of the helmet.
Once the molds were completed and the copies are casted, the next step is to trim off any excess trim/resin. This is done with rotary tools, files and sand paper. Once a smooth finish is achieved, battle damage is applied before a base coat of matte black is sprayed on. Aluminum and different paint washes are added to add the effect of the helmets being used in battle.
Mounting hardware is added to allow the face plate to be rotated along a pivot point. Custom plexi-glass visors are made and installed in the view port of the helmets as well. Final touches such as memory foam inserts and company logo are added.
Just like that! 4 new Lvl 3 PUBG helmets are created. This was a fun project as I had to go back to my previous molding experience and learning new techniques. A huge thank you to Kendra Mio from Sheridan Colleges Special FX and Make Up program for helping with the molding process of this project.
Please let me know if you have any questions regarding this build!
