Rick and Tony came over today with the intent of working on their helmets as well. Dremel's were running hot and plastic chit was flying everywhere. They both got quite a bit of their helmet trimmed out and started assembly on it late in the day.

I continued working on the assembly of my helmet. I used some CA (superglue) to glue the sides together and then reinforced it with some 2" wide plastic strips for rigidity. I also cut out 8" strips and heated them in the oven. Once heated I put them inside the bottom curve of the helmet and let them cool in that shape. With some Goop glue, I then clamped it all together and let it dry. This really made the helmet alot sturdier than it was originally.

I then used some bondo to fill the airhole divets on the top of the helmet. These divots came from the vacuum form process, so this is one of the easier solutions to fix this.

I also started work on my aerators. As you can see in the photo below, I used a Cam Assembly Kit and Aerator Kit from Ace Hardware. The profile is pretty close to the actual design, so I thought they would work out great. Plus, since they're real Aerators, I can put my cooling fans behind them in the helmet and pull in fresh air.

The last thing I did yesterday was to put some Bondo around the seams on the ear pieces. I want to try to have a "seamless" look to my helmet. Also, in the picture above, you can see my metallic base spray paint on the top of the helmet.