Saturday, July 27, 2013

Part 2 of The Making of the Mercury Space Suit Helmet

After a nice bit of work with the production of Moonfleet for Sky, I'm getting a chance to finish this post!
I popped the others out of the mould and naturally they needed a little cleaning up and some filling and sanding. And painting with filler/primer and sanding and painting with primer.

Also to be done were the pivots for the visors. I did them up on the lathe with a slight dome for a nice reflection. Also those little PVC bushes.


I did up the neck rings on my CNC router. Here is a picture of it just cut. Many times doing things by hand is quicker than cncing but in this case it would have been a nightmare. This is 2mm aluminium.



Then the acrylic dome arrived from the UK. I managed to get two helmets from one dome. The visor was by far the trickiest part of the helmet.
The problem was a chicken and egg syndrome. I couldn't make up the components untill I had a pivot point on the helmet to align them to but I couldn't mark the pivot points without making up the visor. So I assembled a visor and taped all the parts together. Did a temporary mark and gradually assenbled the parts constantly rechecking the fit and position. I'm sure all this would be very easy with CAD...

 
 
 Then a paint job. The paint needed 3 coats. It was very transparent unfortunatly. Also two coats of clear gloss.I let that dry over night.

 Then it was just a case of making up a few more gubbins and perminantly assembling all the bits and fixing them off, some with nuts and some body filler.
I was very happy with the end result, so was my client!

3 comments:

  1. This is awesome! Where'd you get the domes from??

    ReplyDelete
  2. The clear acrylic domes came from a supplier in the UK. they are easy enough to find from display suppliers or acrylic fabricators. The name of the company escapes me right now... thanks for the comment!

    ReplyDelete
  3. I got the dome from "Project Plastics" in the UK. Cheers

    ReplyDelete