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Gandhi: 17' Tall Cardboard Avatar

Step 4Projecting, Tracing, Cutting and Scoring the parts...

Projecting, Tracing, Cutting and Scoring the parts...
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  • projector.jpg
  • diagram-4x4.jpg
  • diagram-close.jpg
  • joe-band-saw.jpg
  • knife-scoring.jpg
I created the Gandhi figure in sections made from separate uses of the Pepakura diagraming process. My progression went as follows: head, hands, legs and feet, waste, torso, dothi. Each of these parts of the overall figure were separated in Blender, saved as individual obj files and exported to Pepakura.

I completed each body part before moving on to the next one.

1) Projecting: Using the transparencies and the overhead projector, I projected the diagram onto a 4x4' section of cardboard, using the outermost edge of the projected image to line up with the edge of the cardboard. The cardboard was attached to the wall using masking tape.

2) Tracing: Use your ruler and different colored sharpies to carefully trace the lines and note the numbering of the Pepakura pieces as well! Double check your work here as if you miss something this can make the assembly process very challenging!

3) Cutting: I used the band saw for the first round of cutting of the shapes that were drawn on the cardboard, being very careful to only cut the solid lines and being aware of the tabs, etc.

4) Cutting part 2 There are some details that are just impossible to cut effectively with the band saw, use your mat knife to finish each piece.

5) Scoring: Follow your markings for "mountains" or "valleys", use your straight edge and your mat knife to carefully score the cardboard - I found that generally two passes with the knife did the job - PRACTICE your scoring skills on some scrap cardboard before working on the actual diagrams. The tricky part about this step is that you will need to score at least half of your job on the side of the cardboard without any markings - do all the scoring on the marked side first then use your sharpie to make tiny black marks at the points on the ends of the lines to score on the other side. Always remember to double check yourself during this step (measure twice, cut once as they say...).
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Author:delappe