How To Slush Cast a Prop Helmet

[@TheGardenSnake]

I was the Rocketeer for Halloween in the third grade. My mom made the helmet from a milk carton. It was bitching. My mom was a boss. I never once had a store bought costume.

[@superbmediacontentcreator]

Yea, another irrelevant KZbin comment... your Mom is the best... now if she could only make gags... for you...

[@TheGardenSnake]

+Riki B. Eyestarone the thumbnail is the Rocketer helmet, I'd guess you haven't seen it.

[@Pjiggy]

+Riki B. Eyestarone Are you an orphan? Did your mom not love you? what pain are you holding that made you lash out in such an unnecessary way at this stranger on You Tube?

[@monte6777]

Riki B. Eyestarone What the fuck are you saying? You're telling me to learn english, but your sentence structure and grammar is not only dreadful but incomprehensible. It's a nice story that someone told about the helmet in the thumbnail. Why in god's name are you so angry?

[@MrDeathray117]

+Riki B. Eyestarone The helmet in the video is the rocketeer's. The guy said his mom made him a rocketeer helmet when he was younger. Clearly there is some relevance here. I can't fathom why you are getting so exercised about someone sharing a story.

[@slikrx]

I really wish they would include "materials used" in the description... Also, a "time elapsed" would be interesting.

[@Banehorse]

This

[@ryanbarker5217]

@@Banehorse didn't he mention the materials in the video?

[@andeyking]

@@ryanbarker5217 Yes, as well as the time taken for the entire casting process.

[@bryceelischer819]

Everything is smooth on. For the resin they’re using Smooth-cast onyx

[@NerdyGeeky]

I really love these moulding/casting videos. I want to get into this myself very soon and all of these videos are really informative and make the whole process seem less daunting for a beginner like myself :) Thanks guys!

[@matthewprince6157]

I love Frank, He's matured so much since his first season of Faceoff. Awesome video. Keep up the good work.

[@catherinefisher6188]

He’s like a totally different person! He was such a jerk on that first season & now he seems like a pretty good guy.

[@scratchcrafter]

my favorite helmet, i made one from scratch with leather, then hardened it and turned out pretty good. Thanks for posting!

[@r2witco]

That was awesome to watch, thank you! Frank and Volpin are a couple of my favorite prop makers, was stoked to hear Frank mention them.

[@ScrapwoodCity]

Pretty awesome technique, thanks for sharing!

[@ahikernamedgq]

You could wear a headlamp while doing that to make it easier to see inside the cast. Thanks for the video, Tested!! Great stuff!

[@andrewalexander7363]

Yup, a headlamp is about the best for working inside a helmet.

[@CProductions27]

Would love to see Frank and Adam do a one day build together

[@MatthewClise]

These vids with Frank are always a treat. Thanks for sharing your knowledge with us! It truly is inspiring.

[@lordquinn1605]

I would love to have a helmet like this. Rocketeer is one of my favorite movies.

[@jan-roarbernhardsen7626]

Great to see how you made the helmet. I seen it before, but its always diffrent shapes. Have a nice day

[@walperstyle]

I'd like to know more about how to make the mold in great detailed steps. (I may be purchasing a CNC machine, and I can see amazing possibilities)

[@BradM73]

Are they still doing the millennium falcon build?

[@ThePolyesterPimp]

That lego build?

[@BradM73]

+The Polyester Pimp no, the DeAgostini studio scale build. It was a tested Premium series.

[@DaedalusProps]

I saw Harrison do this with a Thomas Daft Punk helmet. Drunk. It was amazing.

[@FSXtremeVideos]

Even though I'm from after the rocketeer came to the big screen, I absolutely loved it as a kid. Had a wave of nostalgia and watched the movie again last week and it was amazing after not seeing it for 14 years.

[@SeanOzz]

Frank, I have a tiny toy storm trooper helmet I want to mold. Do you think it needs to be a two part mold instead of a one part? I plan to use silicone for the mold. It's an original storm trooper. I'm sure you are super familiar with that helmet design. I am afraid due to the curve of the bottom of the helmet it wouldn't work as a one piece. Especially since I want to cast it as a solid chunk of silicone when done. Any tips?

[@Swarm509]

I'm not a professional by any means but for the mold making and casting I've done I would say give it a go as a single and see how it turns out. You will learn a lot just from making that first mold. The same goes for that first cast (where the air bubbles go, where it pools, how it demolds, etc). If after that you are not happy try a two part mold. Get some extra material and have some fun experimenting.

[@SeanOzz]

+Swarm509 thanks. Yeah. I just can't see a single mold working on this since the bitten is not flat. Unless maybe I use clay to build a mount under it which could double as a pour in spot as well. Just afraid that one high side would not fill up properly when casting. I might just go for it and see.

[@Swarm509]

How did it go?

[@SeanOzz]

+Swarm509 I've been out of town. No time yet.

[@xtianor]

these Last videos with Frank are awesome.

[@i.am.adrian]

That's one clean cast! Nice work, Frank!

[@ryanmpatrick8787]

Frank, how do you determine volume so you know how much resin to mix for a helmet like this? i understand they get progressively smaller, but how do you come to the 8ounce number for the first batch?

[@ShadowMystic7]

I'm willing to bet it was just an experienced guess. I think it was mentioned in the lightsaber video that he hasn't to estimate a lot. You can do some math to get pretty close, but not exactly.

[@seanamlaner9241]

A typical rotocast setup will use between 1/5 on down to 1/3 of the total volume of the original object. The ratio is also determined by the shape of the object, the use, and how big/small the object is. For example, if it's a hollow rotocast object that isn't a helmet (lets say a foot tall vinyl character), you can use a ratio like 1/5 and then backfill the interior with an expandable foam to ensure the cast object has proper structural reinforcement. If making a helmet, you wouldn't backfill with foam and could go with a ratio of 1/4 or so as a starting point (depending on if you hollow cast in layers or in a single batch). Oh, and an easy way to determine your objects volume is by pouring dry rice into the mold to figure out the total volume, then divide that by the ratio you want to work with, which then gives you the amount of resin to mix (based upon how many separate rotocast batches you will be making on a single mold). Don't figure out the volume by pouring water in your mold, any moisture hiding in corners of your mold will mess up any future casting ;-)

[@HashSl1ng1ngSlasher]

that was super interesting to watch happen. Love this channel.

[@fryncyaryorvjink2140]

I've been wanting to make a stig helmet, thanks for reminding me!

[@fryncyaryorvjink2140]

+Lucas de Abreu i looked it up once, it was $600

[@3dcreations801]

That looks to be a beautiful fiberglass and silicon split mold, any chance of seeing a video on its creation or the creation of a similar mold. The way it joins looked perfect.

[@CnijnDsD]

Interesting video, thx! You guys also have a video on how to make the fibreglass shell and rubber mold?

[@Velobetty]

It's nice seeing Crouch End on Frank's t-shirt as that's where I live; right next to Nelson's shop! :)

[@IgorKolar]

Would it be possible to fix an accelerometer to a cast, that could record which way it's facing, for how long, and then used that data to run an arduino based three servo jig to repeat the process ?

[@shugobhastudios]

its nice to know this industry will hypothetically survive the ai/robotic workforce advances, just seems like a lot of judgement calls/aesthetic decisions that will retain it as a profession by humans

[@MBodinger1]

I would love to see the whole process for this Helmet Molding , casting and painting

[@coltius]

Was there ever a follow up video about finishing the helmet? I haven't been able to find it.

[@shellumus]

Why matrix mold this compared to brush on molding? I see a glove mold wouldn't work. Was a matrix used to no seams? Thank you

[@billsargent3407]

Just about the first visit to Adam Savages cave involved him showing the work on his Rockateer suit. bet this is for it..

[@friartuck103]

This is my favorite channel, I'm giddy when I see s new video.

[@friartuck103]

Oh, and "shrinkage"... lol

[@klavakkhazga3996]

Interesting! Can you make a video on how do you make those kinds of moulds?

[@JPorkins88]

Check out the other mold making videos on Tested.

[@emctechnician]

Can we get details on the mould making?

[@nukellavee]

Could you guys make a video about the process behind making the shell and rubber parts?

[@direwolf8703]

if there was something covering the seem of the mold would that eliminate some of the sanding? or like the mold was slotted so the inside was flush

[@ThumpertTheFascistCottontail]

Maybe a helmet like this could be done with a glove mould. No seams to clean up after casting.

[@Surryfox]

Does this technique just work for resin? Or can you do the same with say.. silicone or other materials? For example if I were to make something that has more of a fleshy consistancy that wasn't rigid would this sort of thing work?

[@42pyroboy]

The rocketeer is and always will be my all time favorite movie

[@preferredimage]

So does Franks shop have a website you can order casts from?

[@shellumus]

Would you matrix mold a helmet that has an opening like a magneto helmet?

[@inkno701]

Love the Winchester Tavern shirt! "Go to the Winchester, have a nice cold pint, and wait for all of this to blow over."

[@catherinefisher6188]

Is there a video where they show how they made the mold that they used for this cast? I’d love to see that!

[@saundersdane]

Fun stuff..thanks for sharing....that rocketeer helmet rules!

[@bryceelischer819]

What a beautiful mothermold. Very nice

[@kitaryakysubae3156]

Every hero nowadays has an evil twin. I think it should be painted silver, then have a translucent black/ navy blue gloss over it to give it a black steel perlecent effect with mirrored visor and maybe accent pinstriping in a titanium paint over the top of the fin with some accent pieces would look really cool and put like a midnight silver/ midnight blue clearcoat over the whole thing would look awesome. Give it a burnt titanium like pearlescent look. I have a fondness for pearlescent metallic like colors. Also the burnt titanium look would look really awesome

[@fulfathomfive]

Frank, would you ever do a Rocketeer cast just like that and sell it? Would love to finish one to mount in my shop.

[@PleasantlyLee]

Breaking off the flash on that sound so satisfying.

[@terryrooney8127]

This is an excellent video, very helpful.

[@greyareaRK1]

I'd be worried about the fin - how did you ensure it was fully coated? Gorgeous helmet.

[@chicagokones5563]

Great episode Norm and Frank. Always loved the Rocketeer helmet. I'm trying to finish up a parody sketch of Rocketeer unfortunately my helmet don't look like that lol.

[@papaprime5187]

I wish I had money for this. I have always been fascinated with casting

[@MiamiNight01]

Is the resin already in black color?Or how can I tint a resin before pouring?

[@bazuka420]

where do you get a large amount of modeling clay for making something to cast im trying to make a bebop and rocksteady mask like how you made zoidberg

[@bowlofpie3205]

He just collects from anything he owns i believe

[@bowlofpie3205]

i also believe he uses silicon

[@bazuka420]

you misunderstand the question i need clay to make a sculpt to silicone mold a a form

[@lasarith2]

Go onto Google and search art stores near me .

[@bazuka420]

ive gone to every one in 2 cities they only have small amounts of colored clay not the right stuff

[@RDPproject]

Go to the *Winchester*, have a nice cold pint, and wait for all of this to blow over...

[@CthulhusDream]

Awesome! More Frank!

[@TimothySnowman]

I may have missed it, but what material is the jacket?

[@arletpaz8010]

what was the thickness of all those batches ?????????? @10:40

[@stevenrwilkes]

When I saw the fast house hat I knew you ride dirt bikes. When I saw your crf450r then subscribed because I like that. What year is it?

[@DxManiac100]

Is it possible to slush with scilicon?

[@dubwars]

Frank makes these things look so simple, yet I'm sure I'd struggle if I tried it.

[@newzerozeroone]

So did you guys ever finish this in a later video? I'm having trouble finding anything

[@newzerozeroone]

I don't think they ever answered you guy.

[@StephenDanielAddeo]

So where do I buy the helmet?

[@amtank]

This!

[@Parcolai]

What's the part shrinkage like?

[@mmustangg2]

Where's the video of the finishing? Would love to see that!

[@JGDeRuvo]

Can you do clear resin with this technique?

[@darkback2]

How do you make sure the resin is mixed properly? We tried to do a resin mold and there was a lot that never cured. :-(

[@LowellMorgan]

If the color isn't enough, or if you're mixing something colorless, then mix and pour into another vessel and mix again. That way there won't likely be anything hanging on the sides of your cup. Also, mix with something flat and square so you can scrape the corners. I use tongue depressors but I cut off the ends so they're square.

[@Lockdown3254]

Not sure if I missed it , but does he sell helmets somewhere? Would love to buy a Rocketeer one!

[@repalmore]

I was wondering, could it be slosh and not slush? You know, sloshing the casting material around the inside of the mold. Just a thought.

[@patfilice]

So cool would like to buy one

[@gogeta2319]

What is the outer jacket made from for this mold?

[@TheZombiegunner53]

where does norm get his shirts?

[@SkintSNIPER262]

What material was used for the shell?

[@FlorencePiPropsandDolls]

fiberglass

[@velen966]

I really want to know how Frank make that master mold.

[@cakelton]

Can someone answer this please? What can I use to cut the helmet after i slush cast it to make eyeholes? Also what can i use to smooth it after i cut it? Someone please answer.

[@WakeNBakeMusic]

personal favorite is a dremel with a cutting head, and some high grit sandpaper to clean up any edges. Possibly a set of metal working files to clean up the shape if you aren't comfortable cutting all the way to the edge of the eye (sorry its late as fuck, but hope it helps)

[@JeffLafferty]

Very cool!

[@JeppePaaBjerget]

I once work in a plastics factory. where the mold was the size of a car, and the oven they came into was about three stories high. The method was the same.

[@kaivallon1865]

Does anyone know what is the purpose of the circular marks on the mold shell?

[@klg501]

Sure, it is to make sure the mold locks together.

[@seanamlaner9241]

Those are called "keys". They help to ensure the two halves of the mold is properly lined up when you go to cast. The more keys, the better typically! I've seen some molds end up with minimal keying and the final cast ended up slightly skewed between the two sides. Kind of humorous, but not when under a deadline ;-)

[@kaivallon1865]

+Sean Amlaner The black circles that look like 8s and 0s? I'm familiar with keys but those just look like magic marker to me, am I missing something?

[@seanamlaner9241]

Oooh, apologies, I misunderstood the question! Hmmm. I can't say for sure what that might be, BUT, it is possible that those are A) vent holes in the outer shell to reduce a possible suction effect between the shell and mold inside or B) possible holes to identify certain keys in the rubber mold? Again, not 100% certain, but the two answers are based upon past molds made with these two options listed.

[@vaton9]

could you do a storm trooper helmet with this method?

[@twitchstreamshuly691]

I love this vids. I have a massive undertaking making a 'metal sonic suit' aka Metal sonic meets iron man. I'm trying to figure out wich silicone to use to cast the initial sculpt. and to do it right since I've spent about 50 pounds of clay on it and over 60+ hours of working on it. Do you guys have a specific silicone you use for casting? and any tips for casting large helmets with it.? And ignore the DrunkCrash plays in my username. I was too lazy to log into my main youtube account instead of posting from this one.

[@ListerDavid]

Could we see how to make the shell for a prop like this in a future video please.

[@KYMXER59]

Holy Cow a Fast House hat. Moto on!

[@KYMXER59]

Hey Oh! CR450F in the background!

[@VariusMayhem]

I got a question if you're still reading comments on 3 year old videos... What if I wish to cast the helmet out of something like dough instead of resin?

[@superbmediacontentcreator]

Frank is like a good chef that doesn't really know how much of what ingredients are required. His "oz" estimation of his batches had a variance of about 40% which is a huge margin. You've really got to tighten up your measurements. Is it 3 oz or 8 oz???

[@Nunya_Bidnez]

I bet holding a palm sander or strapping one to your wrists would kill all worry about bubbles

[@cert650]

Awesome. By coincidence today will be my first try to cast a helmet. And I'm sure something will go wrong. :3

[@lp.shakur]

well, thats the beautiful part of learning, isnt it?

[@quinn1401]

So, how did it go?

[@cert650]

Quinn first was failed, next 2 better, but not without flaws. pp.vk.me/c626118/v626118816/17b7f/TeOfjzgkpbc.jpg

[@platypusgov]

Man, I want that helmet!

[@Apollo_Vanron]

AWESOME!

[@dataking3784]

thats great bro

[@BlazingLaser]

Where can I get a Rocketeer helmet like that?

[@burpitola]

BlazingLaser ...make one.

[@ChoccyMonster16]

It seems that Norm's finally learning to keep quiet and let his guests speak. Love the videos here on Tested but that's one thing that's always slightly annoyed me. Well done! :)

[@statesmancomics7284]

Are we able to buy these mask?

[@jaxnean2663]

Neat job

[@garethwood6587]

So where can I buy this helmet???? :O

[@rocketn8]

Happy 25th Rocketeer

[@definitelynotteun]

where can you buy them ?

[@superbmediacontentcreator]

You're an idiot...

[@superbmediacontentcreator]

Yea... exactly... where can he buy the helmet that someone else made... what a dope... go to a costume shop and quit exposing your stupidity by leaving dumb comments...

[@sierralarars]

Riki B. Eyestarone .... You cant exactly get these helmets in a standard 'costume' shop... fyi :) Think before you go 'exposing your stupidity by leaving dumb comments..' :D see what I did there?! :D

[@superbmediacontentcreator]

To have left such a stupid comment is not to have read mine idiot... my point is that if they don't get the point about what they are being shown then buying a vacuum formed a helmet from a costume shop is their only answer... see what I did there and how pointed out how you can't even pay attention or comprehend a simple few sentences... how stupid an idiot are you... do you just sit out there thinking of how you can show the world your lack of intelligence and/or comprehension...

[@sierralarars]

Riki B. Eyestarone Your comments viable to me 1 - You're an idiot... 2- Yea... exactly... where can he buy the helmet that someone else made... what a dope... go to a costume shop and quit exposing your stupidity by leaving dumb comments... None of what you have just said is to do with buying vacformed helmets... it is not even mentions... nor even in the video... get off your high horse dude! To buy helmets such as in the video you need to go to an independent artist or an sfx studio. Not your every day costume shop. Please stop making yourself look stupid, child ^^

[@caedus4751]

love the shaun of the dead reference, frank. Winchester tavern lol. \/\/

[@franciskramm1190]

I want one of these helmets.

[@TheBigBigBlues]

Put it on! Put it on!

[@InsomaniacFiles]

Let's go down to the Winchester!

[@tatopaz4364]

Thanks Great Vid!!!!!!!!!!!!

[@DamianReloaded]

Cool!