Printed the larger/original size. LOTS of sanding. Made up a magnet mount for the mask instead of the swing arms.
What finish/polish/paint/primer did you use? It looks really nice!
This is standard automotive paint bought from Canadian Tire. The primer is the cheap stuff - starting with the cheap value color grey, followed up by the sandable black. I went through a few layers of primer as I coated the plastic then sanded to find the areas that still needed filler, until I was happy with the "flatness" of the surface. (use a light touch with the sandpaper - you can go right through your outer shells and need more filler....)
The gold and red are the Dupli-color, though I don't recall the specific shades at the moment. I know I looked them up via Google and found a match in the Dupli-color. Those paint cans are long gone, but I'll see if I can track down the specific colors.
There is no clear-coat finish on the model. After a year and some of showing and storage, it has a few scuffs that could use a touch up but the paint job has held up well.
Since you mentioned that you dealt with a lot of sanding I just have to ask... what safety precautions did you take? What types of respiratory safety equipment and what type of ventilated environment do you use?
I am literally coughing up blood and plastic and am very concerned about the hazards of sanding ABS.
I did mostly wet sanding to remove the dust issue. For the most part, I sanded the helmet in the kitchen sink dipping it under running water when dust started becoming noticeable. Obviously I was using wet/dry sandpaper though.
how much time and filament did it take?
Approx 100 hours to print. With 20% fill, 0.2mm layers, 100mm/sec. Some parts needing to be printed a second time due to various issues, but mostly typical printer problems. At the full/original scale, it took approx 1.2Kg of plastic. At 80% scale (I had to print two...) it only took about 3/4 of a spool. 80% scale is a little too small though, so If I have to print another it will be 90% scale.
do you know what your general size is in say a motorcycle helmet, or perhaps some of your head measurements? Trying to avoid what you went through and get the size close enough the first time.
The pictured file is at the default scale for the model. We printed another at 80% scale and it came out a little small (but workable). If I need to print another, it would probably be at 85 or 90% of the original size.
You already sort of said that, I was more interested in YOUR head. What size is your head in a known helmet size so I can compare my head and print a good estimation for me. Or just the general sizes of your head.
the head we made the original for was approx 10" in length. I know I take a hat size of 9, but have no clue what that translates to.
So I looked up a hat size chart, and 9 isnt even on them... Do you happen to have a pretty large dome? Don't mean to be rude, just trying to judge for myself.
finally found a chart that has 9, something over 28" circumference?
Well, like from your forehead around to the back of your head circumference, and then from under your chin to the top of your head are good measurements to compare with. I dont mean with a straight ruler, need a tailor band type of measuring tape.
NP. The numbers above do not take into account the finishing time. There is about another 100 hours of sanding/filling/painting. But that is more a factor of my finishing skills (or lack thereof). I used Evercoat Poly-Flex for the filler (http://www.evercoat.com/productDetail.aspx?pID=8)http://www.evercoat.com/produc... - it flexes with the plastic. Bondo will break if there is any flex. For glue, I used the standard plumber's ABS glue from Home Depot.
If you do print this, try to thicken the back bottom pieces of the helmet some. I'm seeing stress cracks there at the joints between pieces. There may not be enough surface area for the glue to give a strong enough joint. So thickening those pieces a little will help with gluing and preventing flex.