I'm just going to clear any confusion before you watch this. I produced two versions of this. There is a small version (the one you are building), and a giant version (not available). Here is a time-lapse of me building C.E.V.I.N. and comparing him to the larger version. To make your own larger version, feel free to modify the files and show me how you did!
I've entered this model in the Halloween Decor Contest. If you like this project, please vote for it!
Step 1: The Design Process
This papercraft began as a school project. The model is based off of a sketch I made earlier that year. I really didn't need anything fancy. Instead of box-modelling in some professional program, I just started from scratch in SketchUp. Once the design was completed I transferred it to Pepakura Designer and "Unfolded" it.
Step 2: Preparation and Materials
For this project, you will need the .pdo file (download it above), Pepakura Designer (or at least Pepakura Viewer so you can open the file) and a printer. The materials required include: Exactly 41 sheets of 110lb cardstock (or chipboard if you are scaling up), glue (hot glue or tacky glues is fine), a cutting/scoring tool, a clear/dry work space, and most importantly, PATIENCE! This took me around 6-7 hours to complete and the giant one took almost 3 weeks!
Step 3: Building
I have already organized the pieces to make construction less confusing. The top row consists of all the parts for the legs. The second row contains pieces to support the two halves of the head/body. The eyes and teeth are located in the third row along with the flat circular ends of the halves. These are separated in the piece layout (see image 2) so it is recommended you combine them as well as reinforce them with cardboard for extra support. If you have a better solution to this, let me know so i can fix it. In the fourth row is the top half and the bottom half is in the fifth row. Build these in segments and combine them later when they are all completed. The model in the file is disassembled so you can better see the parts. You will need to reference this during the build in order to not get lost. You should be able to figure out how most of the segments connect and pieces such as the teeth and legs can be placed where you want. Refer to the video for extra help with this. Please contact me if you need more help.
Step 4: Finishing Up
You should have most, if not, all of the construction completed at this point. Now's your chance to add something or paint the model (see how I painted mine above). You can even texture (digitally) the model if you're feeling up to it! If you need more reference for texturing or an actual 3D file then I can provide one. Also, please send me pictures of your completed model! I would love to see them! Thank you for taking a look at this project. I hope you enjoyed it. Check out my YouTube channel (https://www.youtube.com/channel/UCIKLGL-HcaHHuxSFI4FFa-Q) for more project videos and tell me what you want to see instructions for!