Custom-made helmets... not for "special" people

I haven't seen this one in the archives, so here goes.

You've seen shows like "Power Rangers" or "Power Rangers In Space" or "Power Rangers In My Pants" or whatever. In many of these series, they utilize custom-designed helmets.
They aren't simple motorcycle helmets as far as I can tell, because there are literally two halves to the helmet, front and back, which are on some sort of hinge mechanism located at the top of the helmet. These two halves almost "wrap" themselves around the wearer's face, locked together by two simple clasps.

Here's the question: Anyone know how to design a helmet like that or where to obtain one? Plus, how would you put a design on the helmet (i.e. the star design from "Power Rangers: Zeo" as compared to the "tyrannosaurus red ranger" from the original series).

I know that all Power Rangers-esque shows come from a brand of entertainment called "sentai" (not to be confused with "hentai", which is cartoon porn), and I have tried finding (English) information on this, but have come up with nothing. I have tried the various series (i.e. JAKQ, Zyuranger, Dairanger) and come up with nothing.

Any ideas? Post 'em here.

An award? Really? Hmmm... can I club people with it? Is it that heavy?

I thought that it may have been some sort of a flaky cheap plastic shell for the basic helmet mold initially, but I was wrong. There was a scene in one of those shows when the "white ranger" (not to be confused with the ivory or eggshell rangers) took off his helmet. It almost looked padded, much like a motorcycle helmet would be.

Besides, I don't think that a flimsy plastic shell could stand up to all of those flips, kicks, and shocks that the actors (and the original actors in Japan) put them through.

Stickers are a possiblilty, but there must be some sort of support. I thought maybe it could be sheet styrene, as I have seen things like Darth Vader's helmet made of this substance before, but that has a limited durability as well. I may have to bounce this one over to the other group.

(On a side note, when they had a casting call for the Power Rangers a few years back, I was on my way to go try out. However, they found out I was 6' 8" at the time, and they needed someone under 5' 10". Had to match up with those short Japanese guys, y'know. Their loss...)

later
Tom

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What everyone seems to forget is that once we look past race, religion, gender, and all that, everyone on this planet is first and foremost...

...a PERSON

You could make one if you know how to sculpt. Heres a super simplified quick rundown:

1.buy 25 pound bag of plaster known as 'hydrocal'. cost: about $15 or more

2.make mold of your head for use to sculpt on as well as making a negative mold of your finished sculpted helmet. (you need to go find a lot of info on this before you try making a facial mold)

3.take cast of head and wipe a mold release on it in every possible area but not to thick like. (youll find better info on what kind of product to use as a mold release than anything i can remember) then after appying the mold release cast the 'negative mold' of your head, and after its cast youll have a perfect likeness of your head to sculpt upon for a perfect fitting helmet.

4.buy LARGE amount of sculpting clay such as plasticene. cost: about $30 or more for all of it

5.take final dry plaster cast of head and start putting clay on it and sculpting it how you want it. But some sculpting tools. Price: about 15 bucks for a few decent tools.

6.take final sculpted helmet and depending on under cuts (lets just say their are none and that it just requires a two part mold) you can just divide the clay in half with playing cards (the standard laminated ones that everyone uses, new deck only) down the middle. Now, apply the plaster preferably a thinner coat first and then a thicker one on after that one has dried.

7. after the the mold you just made has dried (never rush on letting it dry, leave it for a day) remove it (the clay sculpt will be ruined so you better have done a decent job casting it) and then you can do the final cast in something like urethane resin or fiberglass resin.

8. casting it in fiberglass/urethane/whatever resin and or vaccumforming it. well this part would also take a million steps and i havent done this anyways so....But as far as the price goes the fiberglass can be bought in large quanitites at boat shops and auto body shops for real cheap. Like 10 bucks a gallon or so. the urethane is much more expensive and which of course means its better in quality.

the low/no budget people may be able to use caulking silicone and plaster as their molds bondo mixed with resin for the helmet itself, and some thin plexiglass for the visor.

foam is available at fabric stores, the hardware, silicone, plaster and plastic at hardware stores, the bondo and resin at auto shops. check out the above metioned books for somewhat detailed instructions on all of this stuff.

you can rough shape the helmet out of foam insulation panels, spread some wood glue on it to make the clay stick better, and sculpt the final detail in clay, this way you dont have to buy as much

good luck.

Thanks for all of the help. I never imagined what kind of an underatking this would be. While I am tempted to try making a helmet and some armour right now, I'm gonna hold off on a while. But, should I make some sort of wacky helmet, rest assured, you will see it.