I have used this method on about eight helmets and it works really well. It's basically a one-stop-shop for all Halo related pepakura files. Peel off the pep file and sand the rondo, trim the edges and insert the liner and wings. Due to many files here now having dead links, and the difficulty of finding individual files amongst forum threads, a Database has been created to collate these files into a singular, easy to access location. Then lay in three layers of fibreglass cloth. Pour it into the shell and rotate it to coat the inside evenly. Then I mix a full cup of rondo (50/50 bondo and resin), using the resin hardener to set it off. Next I wax the inside of the shell with carnuba wax or car polish - three coats works well. I then resin the outside with two or preferably three coats of resin to make it really stiff. The lower rim is intended to suit my pep method - assemble the file, then staple or glue it to an MDF or ply base which has a hole cut out to the same size as the outer flat base. Not too sure about the exact size, but this is based on an old aluminium hard hat and I have scaled it down slightly to fit more snugly. I didn't model the wings, because I reckon they will be much easier to scratch build out of styrene or aluminium sheet. Here are links to A4 and Letter pep files for the Flash helmet shell.
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