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[MysticleRogue]

I'm building my helmet out of a hard hat and home depot buckets.  I'm using bondo to fill in the gaps, but I'm noticing that in some posts people have put bondo on the entire bucket.  Do I need to bondo the entire thing or just use it for the crevices?

[Ohl'd Vart]

Just the crevasses and the seams, typically; any more than that, and you'll be working yourself to death sanding the thing.

Rob

[Raestin Ke'Varek]

Yep.  Just the nooks and crannies for a build like you have. 

Those people that you see putting bondo all over their scratch build, are generally making their helmet out of some sort of heavy card stock, or chip board, then coating it with fiberglass resin.  After that, you begin the tedious process of covering it with thin layers of bondo, then sanding it down.  Rinse and repeat as many times as it takes to get it smooth.

[Bowfanny]

Yep.  Just the nooks and crannies for a build like you have. 

Those people that you see putting bondo all over their scratch build, are generally making their helmet out of some sort of heavy card stock, or chip board, then coating it with fiberglass resin.  After that, you begin the tedious process of covering it with thin layers of bondo, then sanding it down.  Rinse and repeat as many times as it takes to get it smooth.

That being said there are also loads of cake decorators out there that end up with loads more work than necessary, thin is good, build up slow. Hit your nooks and crannies but don't forget that some dings and things are battle damage!