DP Thomas Helmet [Part 2 - Filling, sanding, etc...]

Now, to continue where we left off...

We don't have Bondo in the UK but Isopon is basically the exact same as far as I know. It's a right pain to sand, so after the first pass I decided to start using Polyfilla (which is water-soluble, fine if it gets on your skin and has no fumes).

After sanding, then after priming...

I then cut out the visor and earholes so I could improve their shapes and warp the overall shape of the helmet a bit.

The bottom half didn't quite line up with the top and the visor opening wasn't completely even, so I drilled holes and pulled the helmet into shape with string and bent some old rulers with heat to sort of clamp the top and bottom visor bits.

To make it keep that shape, I gave the inside a couple more coats of fiberglass. The 'sideburns' between the visor and ears got even more... they're over 1cm thick.
I wanted to figure out the size of the inner visor at this point, so I made a template and cut it out from PETG. I punched the LED guides through too and got some of the holes drilled, but doing it by hand (even with a drill press) is really inaccurate. I think I might get it laser cut if not done with a laser-guided drill press.

A lot of filling and sanding was done, and will be done... This is it so far. Because of school I haven't had much time to work on any of my personal projects.