Originally posted in 2018 via Facebook, this archive describes the assembly instructions for our My Hero Academia Wild Wild Pussycat Helmet kits that you can order for yourself from our store!
Welcome to the tutorial for our Helmet Kits! The images in this tutorial are from the first version of our sold kits. Updates and additional information on the current (V3) version of this kit are updated where necessary. Applicable picture are below each section talking about them.
This assembly takes a good hour or so, and the whole thing needs at least an overnight to have the wood glue set up. This kit is plywood for weight and strength, and I instruct the use of wood glue for this reason. If you use any other glue then that's on you.
52 - Laser cut plywood pieces
6 - 3D printed pieces
6 - .125 x .25 Magnets
A masking tape
16 Small screws no longer than .5 inch
A drill (to adjust screw holes)
A drill bit in the size of the screws you have
WOOD GLUE <<< Very important
1. Locate these pieces.
V3 - Lower two pieces will have holes that are diagonal from each other.
2. Locate the main structure rails. The inner most rails are for the bottom, and the outermost are for the top.
REMEMBER! There should be 2 of each piece, and you will need to assemble each half of the helmet as a MIRROR of the other!
3. Check the placement of the bottom rails and the larger inside piece.
See the larger slot on the bottom rail? Those will become the BACKS of the helmets.
The slot on the standing piece should be facing towards the FRONT of the helmets. In the V3, the lower hole faces the front, along with the slot.
Put a small dab of wood glue on the underside of these inner pieces and press them back together.
4. Check the fit and angle of the smaller inner piece next.
The slant of this inner piece should look like this from the side. Remove piece, add glue, replace.
5. Both of these pieces are now done. Set them aside for the moment to dry.
6. Grab your two upper rails and find the four pieces that connect to them.
7. These are two upper rails with one of the connectors. See how only one side fits in nicely? that's how you can check if they're in the proper position.
Almost every piece in this kit has these sort of quirks (haha) where the notches will line up VERY specifically. If it's not fitting, it may be upside down, or backwards.
ALWAYS CHECK YOUR FIT BEFORE YOU GLUE!
8. We will now connect the bottom rails to the top rails with these pieces.
9. Check the fit!
See how the assembly notches match each other on the two front edges, vs the back two edges? That's how you'll know it's right.
Remove piece, add glue to the inside where they touch and replace. Let set up for a moment.
10. Time to use the tape!
Check the fit! This is the back piece. For now, use tape to hold it in place on the top and bottom. Don't glue yet, you may have to move these pieces in the next step.
11. Adorable little baby basket! Now, let's give it some stronger supports.
12. Here are the supports you're looking for. Two of them are already fit inside of the frame. Each will only fit one way! Each may be more circular, to attach by screws to the 3D printed outside, but the notches will be the same.
Once you've found were they go, glue them into the frame, and then ad a little glue to your two taped pieces. You may have to readjust or replace the tape as you do this.
V3 - There are now holes in these pieces, which will made them have a rounder appearance, but the notches are still identical!
Once these pieces are glued up, set them aside to dry until the next step, which won't take too long. The tape should help expedite your helmet assembly, as you can peel all of it off at the end, post-cure.
13. Time for the ears! Find these pieces.
14. Separate them into left and right. Don't accidentally make the same side twice! DON'T!!!!!!!!!!!!!!!!!!!
15. Find the 3D printed pieces that are curved like this. Also find your screws, drill and drill bit.
Notice how there is a top that is very STRAIGHT and a bottom that is more POINTED.
16. V3 - The holes are diagonal! This helps avoid having them backwards OR upside down. Also, the holes should be slightly filleted at the bottom to avoid splitting.
Take a moment to check your holes vs how wide your screws are. Because of how the 3D print is constructed, the hole structure may SNAP the 3D print if the screw is forced into the hole.
Take your drill, and use your bit that's the same diameter as your screws and drill out these holes. Be careful not to go too far and come out the back!
The STRAIGHT part of the 3D print is the top, and the plywood tabs that are LARGER should point in the same direction as this edge.
17. Once your holes are the right size, and you've made sure that the ply and 3D part are in the right orientation, screw through the ply to attach your 3D printed part.
18. This is the right-hand piece. See how the notches fit into this part?
If we were to only put wood glue on the ply that's touching, we'd have a very wobbly piece. Check the next section.
Add wood glue to this setup and tape over the front piece to keep it stable.
I'm holding the whole setup against my stomach, to keep the pieces together while I add the glue.
Either way, make sure that this piece sticks out towards the front of the helmet by the 1/8 thickness. Dab glue, assemble, tape.
This piece fits up next to your small piece for magnets on the bridge.
You can peel back a bit of the tape to reveal the notch if necessary. Don't remove it entirely though, that locking piece still needs to set up in its proper position.
Get your sides even. You don't want the glue to make the helmet setup wonky.
This is going to make your helmet set up in the CORRECT POSITION. That wood glue is going to turn into a rock solid structure.
WAIT 24 HOURS! WAIT! WAIT! BE PATIENT!!! WAIT AT LEAST ONE DAY FOR A FULL SET!!!
Magnets: There are 6 magnets included with the kit. 3 for each side. CHECK THE POLARITY! Use the epoxy in the holes on the top and back portions, and put the correctly polarized magnets in and cover them with tape. At this point, you can snap your helmet together (this will help the magnets attain the right alignment, and the tape will keep them from sticking together) but DO NOT PULL IT APART AGAIN! Not until your epoxy sets up for the recommended time.
CONGRATULATIONS! Your helmet kit is ready for finishing. Bust out the sandpaper, filler primer, exact-o blades and paint, you're ready to take your kit up a notch. When you're finished, please send a picture, we'd love to see your end result!