Crimson Lancer

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I absolutely loved the way these guys look in Borderlands, so, as usual, I had to make one!

As was usual at the time and depending on the project still is, I started off with a pepakura file of the helmet. I found this one online somewhere lost to time.

Building the pepakura. I use white glue for the tabs, just a little dab, then hold the parts together for about 5 seconds.

At this point I've laid fiberglass on the inside and coated the outside with fiberglass resin. This is the first layer of Bondo body filler to help smooth out the curves. I don't use this method any more.

I didn't get any pictures of making this mold, apparently. This is showing the FreeForm Air insert in the visor section that probably saved me $30 worth of silicone.

First sucessful pull! I was pretty worried about that litle furrow in the "eyebrows" around the goggles, but it came out fine! I usually hit that area with a bit of petroleum jelly in addition to the mols release and baby powder, just to make sure it releases. It's almost impossible to see so the slight deformity that causes isn't noticable.