From the research found on WW1 helmets Andy was able to use the measurements found to scale up a replicate template of an helmet to help us create our own. This will go towards the props section of our project as well as helping expand the skills we already have.
Creating the Mould:
1. From the research, the measurements and shape need to be transferred onto a plain piece of paper, so that it is the correct scale and can act as a template.
2. This paper template then needs to be stuck onto a thin piece of styrene, marking the centre point of the helmet.
3. Once stuck onto the plastic half of the image needs to be cut away, leaving the other half of the template attached to the large piece of the plastic.
4. Cut the remaining half away leaving the outline of the helmet on the plastic, allowing you to cut straight lines around the shape leaving a border. This will now create your plastic template which will be strong enough to create the plaster mould.
5. Sand down the edge of the template so that you have a smooth edge to create the mould with.
6. Using the template, attach the centre to a wooden pole so that the bottom of the pole is equal to the bottom of the template. To create the bond between the two materials use super glue and an agent, this allows the bond to be created a lot quicker allowing you to continue with the process.
7. Next drill a hole into a small block of wood, big enough to fit the pole with the template attached inside. There also needs there to be enough room for the pole to be moved around. Then using a PVA glue and super glue combination the block of wood needs to be stuck to a wooden board. ( The PVA provides the strength however the super glue allows it to set a lot quicker)
8. Coat the board and block with a couple of layers of a sealing agent, therefore when the plaster is placed onto the wooden board it will not absorb the moisture.
9. Place the pole and template combination into the hole drilled in the wooden block, ready to start producing the mould. ( Vaseline can be placed in the hole to assist the rotation of the pole)
10. Start placing the plaster in a bowl of water, the warmer the water the quicker the reaction will take place. When islands of plaster start to from on top of the water that indicates to stop adding plaster and to start mixing the two together using your hands until the mixture thickens.
11. Place the plaster into the centre of the board, working your way outwards. Make sure that the template is being rotated regularly so that the shape of the helmet starts to be created.
12. Keep repeating the last step, building up the layers of plaster until the complete helmet shape is created. Remove the pole from the centre of the mould and patch up the top. This mould can now be used as the template to create the vacuum formed piece.
Vacuum forming the helmet:
1. Cut a piece of styrene to 27cm ², ready to use on the vacuum forming machine.
2. Place the plaster mould onto the table of the vacuum form machine; spay the mould with wax so the plastic doesn’t stick then lower the table.
3. Place the piece of plastic onto the border of the table, shiny side up, clamping it into place.
4. Pull the heater over the plastic and watch until waves are created and then start to clear at this point you know the plastic is ready to be vacuum formed.
5. Push the heater back and pull the leaver forward to move the table up, pressing the start button straight after allowing the shape needed to be created.
6. Wait until the plastic is cool before you un-clamp the plastic and separate it from the plaster mould. ( When you can’t create marks with your finger nail or corner of an object, the plastic is cool enough)
7. Cut around the base of the helmet mould, so that the excess plastic is removed leaving you with the desired shape and your WW1 helmet.