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Old 03 June 2015, 06:29   #1
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Fibreglass Helmet Repair

Hi,

I have a possibly 'unusual' problem. I have a fibreglass helmet for a costume, it made it 4,500 miles from Newcastle to Dallas Texas, but fell on a tiled floor in the hotel.

The helmet is now cracked, the crack is all the way through (the helmet is maybe a quarter to a third of an inch thick) and may actually be an inch or two longer than in this original photo. So I was wondering if there is any way to repair it?

I should also probably clarify that I did not make this myself. To be honest I'm not really the most DIY savvy (though I do try my best), so a somewhat simple solution would be preferable.

I have looked on YouTube and seen the whole process of sanding the area around it and using strips of fabric with resin to repair it. However the helmet doesn't need to be the strongest thing on the planet, it's not like I will be using it to actually protect my head, also if the crack was sealed but still visible then that wouldn't be the end of the world as it could be seen to be 'battle damaged'. I am also fully willing to find the type of spray paint used and repainting the repairs.

Thanks for any advice you may give,
Tony

P.S. On an unrelated point, if it can be repaired then I may make a mold of it over the summer and make a carbon fibre replica, as I hear that will be stronger.
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Old 03 June 2015, 07:29   #2
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That looks like plastic not fibreglass so fibreglass will be no good car bumper repair adhesive might be the best bet for it or possibly use an epoxy like araldite to carefully glue the crack back together then disguise it best you can
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Old 03 June 2015, 07:38   #3
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Thanks for the reply. It's definitely fibreglass, might just be a bad photo. Would the likes of araldite still be the best way to go without having to sand the outside?
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Old 03 June 2015, 08:48   #4
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I'd be looking at a compound such as 'chemicial metal'. You'd mix this up then push into the crack / put a layer over the crack to stick it together.

If you can get to the inside it'll look better. If the crack is pretty thin then araldite or a superglue may well hold nicely.
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Old 03 June 2015, 09:17   #5
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If it's 1/3 inch thick and it broke clean through when you dropped it on tiles, then it's unlikely to be fiberglass (which should withstand MUCH greater forces). Any photos of the inside?
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Old 03 June 2015, 14:00   #6
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If it was me... I'd clean the crack out using some abrasive. Then put shiny side of sellotape to the crack and hold it in place with some low tack masking tape.

On the inside mix some pound shop 5minute epoxy up and run into the crack. This in places will run through to the tape which hopefully doesn't stick (if you had easy source of mold release agent that on the shiny surface if tape would be perfect.

Once set, remove tape and fill any gaps with an easy sand filler (either just a basic pound shop job if genuinely cosmetic and dry or two part car body filler). Then sand and paint. If still flexes I'd put some fibre based body filler on the inside if there is room.

I'm assuming access to these components is easier than gel and resin and CSM.
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Old 06 June 2015, 09:31   #7
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Sorry, I hadn't realised there were more replies.

Quote:
Originally Posted by treerat View Post
I'd be looking at a compound such as 'chemicial metal'. You'd mix this up then push into the crack / put a layer over the crack to stick it together.

If you can get to the inside it'll look better. If the crack is pretty thin then araldite or a superglue may well hold nicely.

It turns out I do already have some Araldite.


Quote:
Originally Posted by willk View Post
If it's 1/3 inch thick and it broke clean through when you dropped it on tiles, then it's unlikely to be fiberglass (which should withstand MUCH greater forces). Any photos of the inside?

I've measured an it's about 5mm thick.

I've just taken new photos of the inside and outside:

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Old 06 June 2015, 10:55   #8
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Don't think that's GRP, looks like some kind of resin. If it was 5mm thick GRP, you wouldn't have a clean break from inside to out, you'd be able to see the strands.


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Old 06 June 2015, 11:24   #9
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That's not a helmet, its a Power Rangers head!
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Old 06 June 2015, 11:28   #10
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Fibreglass Helmet Repair

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Originally Posted by A1an View Post
That's not a helmet, its a Power Rangers head!

Dunno why he don't throw it in the bin and buy a new one might be his head that cracks next time after repairing it... Maybe he's a Yorkshireman


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