[ljf]

Very happy with the results - and learnt so much making it - i.e. building my own vac forming table to make the visor.

Loads of sanding and spray painting, in-all I think it took me about 70 hours, but we wore the helmets loads for festivals and parties.

I no longer have the file sadly, but got it from a paper craft forum - where people posted them. Happy to share pics if of interest.

[smith7018]

Wow how hard was it to make the vac forming table? Have you used it since? I'd love a link to a tutorial if you have one.

[ljf]

Sadly I can't find any pics of the basic table we made, but that was actually an easy thing to make once I thought it through.

I basically got a 2 sheets of MDF to the size I wanted (roughly the size of a baking tray for the oven, as I had to heat the plastic in my home oven) then drilled a hole every couple of cm in one of them, then made them into a shallow box - sealing all the places the wood connected with bathroom sealant on the inside and duct tape on the outside. I made a hole in one of the 'side' pieces that would fit my vacuum cleaner hose, and then added more duct tape to seal.

Then I made two wooden frames as big as the largest baking tray for my oven, then cut some heatable plastic to size, and clamped them in the two frames and put them in the oven.

This part had loads of trial and error - ie how long the plastic needed heating, how long to run the vacuum cleaner, how to make sure the plastic didn't end up behind the thing you were forming, how to make sure the think you were forming didn't deform while under pressure.

Email in bio if you want pics or more info.