|Project by DanaBabcock||posted 05-04-2014 10:52 AM||1014 views||1 time favorited||6 comments|
Just finished making this plaque for a retiring Flight Equipment technician who went on to become the State Command Chief for the CT Air National Guard. I cut the helmet in half freehanding it on a table saw. I couldn’t find my laser level to put a straight line across it to mark it for cutting so I had to improvise with a bright flashlight and a piece of cardboard to put a straight shadow on the curved surface to trace!
Once the walnut was cut and shaped I traced the outline of the helmet and freehanded a 1/4” deep groove to inset the helmet shell in with a dremmel tool and a wood grooving bit. Inset the helmet and attached the components using PVC glue, finished with three coats of poly, and added the etched plate from a local trophy store.
I think next time I may try using wood filled to fill the grain of the walnut and get a really smooth as glass finish on one. And if I do another one I’ll definitely be making a template for it so I don’t have to freehand it again! Good thing I’ve got walnut colored wood putty to fill the little shaky gaps between the helmet shell and the wood. On the plus side, the visor covers the worst of it at the top of the helmet where I was cutting against the grain. A plastic glue syringe definitely wood have helped too. It was pretty tough work getting the thick PVC glue into an 1/8” groove with a flatead screwdriver without getting it on the to-be-finished surface.