Time for an update:
A few people on various forums have asked me to show pics when I finaly got arround to molding/casting the helmets... Well here are some! Problem is that I used the last of my supply of mold making stuff (until my smooth-on products arrive later this week) and due to a possible varience in temperature while the mold was curing, I ended up with a few unexpected bubbles. I decided to use the molds anyway to also use up my old supply of TAP casting resin. The Airborne helmets had the most air bubble problems, with the Clone Engineer having the second most. (Though oddly those were the majority of the helmets that turned out well...) The Demolitions Clone helmet prototype sculpt was partially destroyed while attempting to remove from the mold, unfortunate as the mold for it was less than desireable (spelling?). I got a few to (kind of) turn out well, including the antenna. The Galactic Marine had the problem of rarely getting resin into the part of the lower face mask. (I was using one part molds for all these.) I attempted Glassman's process of "cast a removable helmet without dremelling it to death" and had a few successes, but all the failures were to blame on me for getting to rushed trying to do too many things at once.
Ahhh...A trip to the severed head market! Yay!
![](http://img225.imageshack.us/img225/3936/helmetcast01rz9.jpg)
![](http://img225.imageshack.us/img225/5631/helmetcast02un1.jpg)
![](http://img225.imageshack.us/img225/1660/helmetcast03bz3.jpg)
Watcha mean my helmet is too big?!?!!
![](http://img90.imageshack.us/img90/5357/helmetcast04wa1.jpg)
Cody and friends strut across the catwalk with the newest in clone accessories!
![](http://img228.imageshack.us/img228/170/helmetcast09af6.jpg)
![](http://img89.imageshack.us/img89/7403/helmetcast08ev1.jpg)
![](http://img97.imageshack.us/img97/6654/helmetcast07pu4.jpg)
![](http://img89.imageshack.us/img89/9620/helmetcast06bz1.jpg)
![](http://img134.imageshack.us/img134/5266/helmetcast05nj0.jpg)
Well I found these casts did not turn out so great, but there is hope that the Smooth-on stuff I am getting will help me make some better casts.
I am also in hopes that since I will be trying out Fixit Sculpt, that I wont lose anymore sculpts to crumbling apart in the mold...That really sucked...