Molding the helmet... YES ITS A CUT AND PASE FROM ANOTHER SITE lol
First off set your master on a silhouette cut out of your piece then place almost level with the cut out.
Glue sticks close to your master closing out the opening you have.
With clay you will have to build a level FLAT area, this will be the dividing wall between the two halves. Over the flat sheet, cover the entire sculpt with 3/8 to ½ inch sheet of clay.
Add the keys on the top of the mold and the last key on the outer part of the mold. The keys is what will keep the silicone from moving around or falling off the jacket.
Once that is done, add a total of 3 coats of bondo resin with a 2 inch brush, take your time and make sure that by the third coat you the entire clay covered with the bondo resin.
Then cover with 3 coats of fiberglass.
Here is the thing this part will take about 4 to 5 hours once it's done, you have to leave it to cool off and guess what repeat the same on the other side lol...
Flip the mold over, this time you don't need the wood cut out, the flat area of the fiver resin is your working table so DON'T make another clay flat area, work directly on top of the resin table. see...
See repeat all the steps and...
To answer any questions this process does take a long time, you cant rush it as the materials used do generate heat and that is how they cure so the complete process to ensure a great mold is to do it in 4 to 5 days.
Day one 4 to 5 hours make once side of the jacket with the clay.
Day two 4 to 5 hours make the other side of the jacket.
Quick FYI you can do this all in two days, but you do take a rick that the chemicals will harden faster on the second half due to the heat the first half generated for several hours after molding. So it's best to take your time. For those that work with resins and bondo know that heat is the key factor in the catalyst of the chemicals. to much heat will make them gel up faster.
NOW
after all the work is done, yoe get this...