DP helmet repair and mod

[darkjawas]

i got off of ebay a while back 1 DP helmet that was cracked after contacting the seller
i recived a urethene rubber mold of a DP helmet a year back he said to use to repair/make a new helmet
im not sure on recasting views there and im hoping this wont start any with this thread
havent done much with it up till now
finally have some time now to work on them

my plan is this make a roto cat of the helmet from the mold
cut the casting up at least in 1/2 and expande the helmet front and back about 1/4-1/2 inch
bondo/clay repair the seam sand paint then i will make a new mold of the repaired and expanded helmet

[darkjawas]

Have made a roto resin casting of the helmet and taken the dremell to it
3 full cuts and one cut in front above the visor the gaps will be expanded to 1/4 inch all around
then fiberglass resin jelly (fiberglass bondo) will be used to fill in the seams
currenty this week working on gluing in spacers and clamp hold

[darkjawas]

started gluing in shims/connectors to the section cuts
using what i have laying around shims are sintra with jb weld glue with hot glue to hold in place w/
clamps