OK so, the vocoder.
The vocoder was pretty poorly molded, and had absolutely no defintion whatsoever. It simply looked like a lump of fibreglass shaped roughly like a elongated clamshell.
I therefore 'dremeled' out the lines that separate the vertical bars and sanded them smooth/rounded, I also reinforced the rear of the piece with a good lump of fibreglass (P40 - see previous posts)
I then made the mother of all boo boos! I tried to aligned the piece perfectly vertical with the helmet resting on a flat service, forgetting that the original helmet was not symetrical, and this re-mold (Or whatever it is) was probably even worse.
When I picked up the helmet when the epoxy was set and looked, the vocoder was sitting 10-15 degrees off!
1 screwdriver for leverage and a simple cutting tool (Stanley knife) later and it was off. I then resanded the rear and reapplied, this time with acrylic resin to give me time to constantly re-align the piece.
This has come out pretty good, but as you can see from the pictures above (thanks http://www.starwarshelmets.com/), the vocoder on there curves away under the chin, whereas mine simply is a flat piece which juts out.... so today's task is to mold a piece of aluminium mesh, fibreglass, and fill to build this 'piece' up on my lid :D
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