Hi, we're doing some Spaceballs cosplays for a Mardi Gras Parade, and we're having trouble with the A**shole helmets for Dark Helmet's cronies.
I want to make at least 4 of these, so set-up costs can be higher than normal since the cost will spread out, but I want a replicable process to end up with 4 similar looking helmets.
So far we've papier mache'd over some punch balloons (since they are large and round, not oblong like party baloons), but with the weather change getting colder, the balloons shrank while drying and we've got some wrinkly newspaper orbs.
I was wondering if anyone else knew of a good method to make smooth helmet orbs. I was thinking of learning to use Bondo for the exterior but I've never used it before and not sure if it will accomplish the round, smooth surface I'm going for.