Make: Daft Punk Helmet, Bondo


I’ve applied an initial coat of bondo on the helmet. Lesson learned, you want to make sure when applying the bondo to get it as tight to the shape you want as possible. Flatten all of your surfaces with a knife and avoid dripping. My first application of the bondo was too quick and not precise enough. This resulted in a ton of sanding to correct the shape and air pockets where it wasn’t smoothed out enough.


The white you see in the photo is automotive bondo (about $10 a can). The red is the bondo brand spot and glaze putty ($6-7). There are a ton of little air holes in the bondo (look around the jaw line, see lesson learned) so I’m going over the entire thing again with the spot putty to fill them all in.

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