Pepakura is a program that takes 3D models and unfolds them into a series of 2D pieces that can be printed out and assembled. I am new to the hobby, but I've noticed major issues with a lot of the tutorials currently available; they lack information on the finishing process. Browsing through Google and costume forums a lot of people have taken great care to cut, fold, and glue beautiful paper models, but when it comes to painting and detailing the end product, the project goes awry.
My experience is in that finishing process. The main focus of this tutorial will address the painting and detailing stages of a build, taking you from paper to Iron Man (but actually War Machine), hopefully giving you some tips and insight along the way.
Pepakura, from my limited experience, is relatively straight forward but time consuming. Many communities exist on the internet that have posted models and files and many of the major movie and video game icons already exist. This makes the hobby accessible for people like me who want to jump in and try it out without the need to first create a model of my costume on the computer. Take advantage of these communities, they are a resource with experienced users who are willing to help.
DISCLAIMER: This project uses harmful chemicals and tools that must be handled properly. If you are unsure how to use a tool or chemical consult the user-manual or contact the manufacturer. The internet is also a great resource. Make sure to work in well ventilated spaces and take breaks when/if you get annoyed. The work can be tedious, but it is important to keep focused and take your time. One silly mistake or botched fold can mean headaches down the road. Be smart about it. I am not responsible for any injury or damage caused by this project or tutorial. Work at your own risk.
With that said, let's jump into what you need to get started.
Step 1: Materials & Tools
Items in italic with an * are optional but recommended.
Cover Stock/Card Stock/110lb Paper
X-Acto Blade/Cutting Blade
Hot Glue & Gun
Computer and Printer
Disposable brushes (4+)
Mixing Cup (top of Resin container works well)
Spoons/Mixing stick (mixing)
Finishing and Detailing:
Sand Paper (150 grit)
Mixing Cup/Paper Plate
Spatula/Flat Object (used to apply and spread Bondo)
Plastic Spoon/Mixing Stick (mixing)
Nail File (Emory board, can be cut to get those hard to reach places)
Dremel w/ Sanding bits*
Colors of Choice
Wet/Dry Sand Paper (400 grit+)
Painter's Blue Tape
Refer to my other tutorial here. Shameless plug ;).