First up then was to work out the scale. Quite easy as I would just use the papercraft one I had as a guide. Then I cut 3 blocks of 12mm mdf which would form the helmet and neck.
I dont have a lathe but I do have a drill and after a bit of trial and error I managed to make a rudimentary lathe by clamping it to a peice of wood and screwing a rest to the side.
It works remarkably well and soon enough I had this.
Pleased with this I marked and started to drill the portholes.
What a disaster! The mdf just fell apart. I tried to repair the damage with glue and tried spraying it with paint to try and hold the fibres together but it was to no avail.
This would have been a show stopper until I made 2 most amazing finds.
First was an old bucket and spade from a previous holiday in the garage. The bucket had a round tower which was exactly the right diameter. I hacksawed it off, marked and drilled, bit of a sanding and its perfect. The light shines through the plastic however so I filled the inside with polyfiller and its done.
The next find was in one of those discount 'sell everyting' stores in town. By the door was a box of odds and ends and in there i find these 'eyelets'. Don't know what they are for but they are brass and just 7mm diameter. Just the size of the portholes I drilled. So for 69p I got a bag and fitted them. Lovely.
Found these mini screws from an old RC heli project which finish off the helmet brilliantly.