Daft Punk Thomas Bangalter helmet build - FINAL p.20!

Volpin

The powers that be have asked me to split my massive Daft Punk thread into two parts. From here on out, this one will serve as discussion for the silver half of the techno chrome-dome duo, Thomas Bangalter.


(pic is of the final result - for more shots, visit page 20!)

I completed the other half of Daft Punk in July of 2010. Seeing as how you can't leave a pair half-finished, I've decided to start building Thomas' helmet as well.



Read about that build here

So, my process has not benefitted over the past year or so from any elegance, but I'm hoping this will still get the job done. Thomas START!

I started out by drafting the helmet in Illustrator, then printing to scale.



Pattern Drafting onto 1/4" MDF:



These are the component pieces...



...which forms this structure. The idea here is to sculpt the main dome of the helmet first, then add the visor and front chin at a later time.



I had a crapload of insulation foam laying around from earlier projects, and seeing as how I've vowed to never use spray foam again as long as I live, the pink foam get its shot at making the form. I'll be sanding this to shape once all the glue has set up.



Here's hoping this one won't take me another 17 months to finish...

TheNickFox

It may take some imagination at the moment to see the dome in a pile of insulation foam, but I can only say it's great to see this project finally begin!

If this is anything like your normal work, I'm sure it will be awesome.

Now I feel like I need to hurry up on my own Thomas build before you catch up.

Can't wait to see how this all pans out.

...and how many future Thomas builds will use MDF profiles and insulation foam thanks to this.

-Nick

Volpin

Every time I see some poor guy start out building Guy with spray foam and illustration board, i feel a twinge of guilt. That is, by far, the worst way I can now think of to build that form.

To anyone thats done it: I am so, so sorry.

Millsman163

Really? I thought that despite being really time consuming it was a very useful way to do it. I do however think the new way is a little more efficient though, haha. I can't wait to see how this one plays out.

Agent RayBans

"This is like IKEA for Daft Punk." I nearly spit ice tea all over my monitor!

I can't wait to see more progress, this should be a fun ride.

I think I've asked you a few times now, but are you scaling this to be larger like your Guy-Man was, or is this going to be a little more "normalized" in size?

Keep up the good work!

Laamberry

Going to be eagerly watching >:] You've put it in my head that I really need my own Guy helmet...so it's just dumb luck that I searched for the thread today and you had started this one for Thomas! I'm sure it'll turn out great as usual.

juntari

Why do you say spray foam was a mistake? I started using spray foam to fill in the gaps (with the main shape made from foam core) after seeing your build thread and its always worked pretty well. Do you mind explaining why you don't like that method?

Alan Castillo

As Michelangelo said "I saw the angel in the marbel and merely carved until I set him free"

Nice start Volpin

Risu

I'm on the same page as Nick, I need to get back to working on my Thomas helmet! This is looking good already, can't wait to see how it turns out. Are you going to go all out with the lights and everything?

Ares5000

Hey Volpin, amazing work will soon follow I'm sure of it!

I started a pepakura Thomas helmet that is currently in the OCD sanding phase yet again. If you wanted to try that let me know, I've got a plotter that can cut out a .PDO helmet in a few minutes.

I've also found this kit that looks fairly straight forward for wiring a 5x24 Thomas LED display: NerdKits - The LED Array Kit

I'm still trying to figure out just how many LEDs are in the TRON Thomas helmet...

Volpin

Spray foam isn't really sandable. You can try hacking at it with some 60 grit, but ultimately you're limited to carving. Its also not dense enough to keep a uniform shape and can collapse in on itself when you put a bunch of weight (clay) on top of it. I find the pink foam much more versatile.

Also, i had it laying around, so it was free.

Thanks for the offer! I have a half-made Thomas pep helmet, might finish it just for scale reference, but pep and I just don't get along. As for electronics... well i'll cross that bridge when i get to it. Should be fun.

Progress! See the dome now?

Started out carving with a coping saw, then used an orbital sander with some 60 grit to refine the shape. Probably took a bit more off than necessary, but this will need to be built up with bondo anyways to get things exact.



front 3/4


rear 3/4


A trick I learned a little while ago for "sealing" pink foam is urethane casting resin. I tinted some smoothcast 300 and brushed it on top of the foam to give it a tough, chemical resistant shell for the sculpting process

First coat


3 coats dried


I'm pretty confident with where it is now. Think I'll toss it in some rubber then open up a JY thread. Sound good?

Seriously though, things always look so ugly at the beginning. Hopefully it'll look like something more than a ball of resin soon.

juntari

What did you use to tint the resin? I'm always tempted to use food coloring but I could never get a clear answer to if it worked or not

Crix

Harrison, I'm sure you'll end up making this look effortless as always.

Charles Kline

Your awesomeness encourages me to build awesomeness of my own.

Looking great so far!

Gorgot3000

i love your idea to use the mdf pattern to make the right form of the helmet

MrSinistar

Unbelievably awesome, Harrison! Can't wait for more progress pics!

Agent RayBans

I just came across this picture as a result of a chart I made that was published over on Gizmodo.

The guy who posted this says he knows one of the guys who made the original helmets, and posted this picture as proof. I have never seen this picture before and though it was worth posting here!



***Edit

And here's another!

Risu

I may be completely off base here, but did Red Bull exist when the first helmets were made?

Charles Kline

Red bull was created in 1987 in Austria, it entered the US market around 1997

Agent RayBans

These pictures that have just surfaced also match up with ones that have been around for quite some time, released through LED FX's website:





I thought the same thing though, "Has Red Bull really been around that long?"

Icknaybob

Volpin....I love you man. I hope one day soon you will have the Tron version of Guy's helmet done so I can buy it! Your work is beyond awesome. I'm way too lazy to attempt these kind of projects. Keep up the good work and keep posting pix.

Red Bull has been around for a long time. I've been drinking Red Bull since before it was even FDA approved and they used to have "sticker" labels on them.

Spike

Very cool. It's interesting that the light bars seem to have been made almost the exact same way that Volpin went about it.

Shame those are just for Guy, it looks like Thomas was being worked on at the time. Although I don't think they'd provide any practical help in Volpins build I still like looking at them.

Agent RayBans

Agreed, I posted these pictures more so for others to see more than to help Volpin. As you said, hes more or less been there and done that!

I sent a message to the gentlemen to see if he would be willing to share anymore information or photos. I'll let you all know if anything comes of it.

Luke

Were they able to see out of those original helmets?

Also, amazing work Volpin. Inspiring every step of the way.

Spike

I forget where but some interview where they talked about it said they had pinholes to see out of.

It's pretty clear why they got rid of the complex effects. It was cool and worked for the music videos and the rare interviews, but I can only imagine the hassle it must have been. Heck, IMO even the castings of the old helmets were messy and looked bad up close.

However, given what Volpin was able to do with the effects on his, and how compact he was able to keep the cables and controller boards, I have to wonder why they haven't tried going back to them. Surely theres better technology today.