How To Make A Sci-Fi Helmet Part 2 - Design Breakdown, Pattern Making, Vacuum Forming

VACUFORM MACHINE

2 Space Heaters 9 x 12 (need a reflector and flat ribbon heating element)

Alternative 1: to the space heaters 20' Nichrome ribbon and custom made firebrick wire mounts)

Alternative 2: Toaster oven

1' Roof Flashing 20" tall alt: Sheet tin 

12' High Temp Cloth Insulated Oven Wire alt: High Temp 12 gauge wire

3 Way Toggle Switch High Amperage alt 3PDT Switch

Thermostat 

10' 1" x 1" L Channel   alt: L Channel

10' 1/2' x 1/2" x 1/2" C Channel  alt:C Channel

14' 1/2 x 1/2 Square Tube    alt: Square Tube note: the alt stock is 3/4" some adjustment will need to be made to the design

1/4" Wing Nut alt: Wing Nut

1/4" x 3" Hex Bolt alt: Hex Bolt

1/4" Large Eye Bolt alt: Large Eye Bolt 

16' 1/2" High Temperature Weather Seal  alt: Seal note: the alt product will need to be trimmed lengthwise to .12.7 mm strips

6' 1/2" Magnet Strip  alt: Magnet Strip

6' 1/2" Flat Stock  alt: Flat stock

1/8" 6061 Aluminum 14 3/4" X 10 3/4"  alt: 6061 Auminum 

3 Project Sheet 3/4" Plywood alt: MDF

(4) Screw On Rubber Feet alt: Rubber feet

4" Intake Vent alt: Intake Vent

24 Pan Head #4 Wood Screws alt: #4 Wood Screws

1/8" x 1/8" Pop Rivets alt: Blind Rivets

1/8" x 1/4" Pop Rivets alt: Blind Rivets

36 Drywall Screws alt: Drywall Screws

Silicone Caulk - Window and Door alt: Decorators Caulk

2 HP Shop Vac 

Box of Wire Nuts

BUILD MATERIALS

(10 pieces) Floral Foam 4 x 9 x 1 

(24 pieces) .06 styrene sheet 12 x 16

(24 pieces) .03 styrene sheet 12 x 16

Greeble (varies by project)
      Garden centers
      Tower hobbies
      Plastruct

PAINTING MATERIALS

Airbrush

2 Spritzer Bottles

2 Chip Brushes

Assorted Model Paints (model master, testers) varies by project we will be using: gun metal silver, black, grey

Latex House Paint, for distressing varies by project we will be using: light grey, black, brown

99% Alcohol

ELECTRONICS

Assorted single or multi-color leds (varies by project)

24 guage black wire

HEALTH/SAFETY PRECAUTIONS

When working with toxic and/or dangerous materials or tools:

ALWAYS read labels for appropriate use guidelines

ALWAYS wear a high-grade respirator

ALWAYS work in a well-ventilated area

ALWAYS protect your skin

ALWAYS wear eye protection