I've always wanted to make one of these, but i never can acquire the proper materials, so i made one using my favorite crafting stuff, cardboard and duct tape! The result is very sturdy too.
Step 1: Materials & Tools
- Hot glue gun
- Cutting mat
- Exacto knife or other cutting tool
- Measuring tape
- Corrugated cardboard (a large box should be enough)
- Duct tape Gray and tan (optional brown)
- Glue for hot glue gun
- Horn shaped pieces of Styrofoam (Hey, i found some, if you don't have any you easily make some out of cardboard, I'll update this when i do)
Step 2: Start head dome
Start by figuring out your head size. (side note: i cant give exact measurements for anything here, its completely up to your head size) then cut a rectangular piece of cardboard, the width of it should be long enough to go from the top of your head to the tip of your ear when curved, the length should be about an inch above your head size
Now draw a row of spikes on the cardboard, these should be an inch wide at the bottom and the tips should reach all the way to the top and be spaced an inch apart. Start the spikes an inch and a half from the bottom of the piece.
Now break the backing by running it down the edge of a table, see third photo. (credit for this technique goes to Seamster) you'll be using this technique for every piece
lay it out flat and cut the spikes out (as strait as possible) and then break the backing of all the spikes so they can curve inward.
(another side note) Don't worry too much about how the cardboard model looks because you'll be coating it in duct tape.
Ok now hot glue the ends of all the spikes together as shown, try to keep them all towards the center but make it slightly oval so it can fit your head.
When you're done with that you should have a slightly oval dome.
Good news! that was the hardest part.
Step 4: Horn Mounts
Now hot glue both of them to the upper sides of the dome, make sure they're level and strait, i recommend gluing them on with a little bit of glue (so you can pull it of easily if you mess up) until they're alined strait, then add more.
Step 5: Face Plate
Then cut a strip out, (a little more than an inch in length) just short of the top leaving an inch holding it together.
Step 6: Nose Bridge
see the picture, the prong-things go a little lower than the middle of the mouth and should be wider too.
Cut it out from a piece of cardboard and break the backing.
Now bend where i drew the black lines in the second photo.
Lastly, glue the bridge on, it should line up so the curve lines up with the mouth. Make sure the prongs are still bent or else this was a pretty useless step
Now you can cut the eye holes out.
Step 7: Attach the Face-plate
Now take it off and line it up to the drawn marks and carefully glue the face-plate on, this part is critical.
Step 8: Back Plate
Step 9: Neck Armor
Now glue little pieces on the outer side as shown in the second picture.
Step 10: Ridges
Make a long inch wide piece to go across the top and the back and shorter pieces to go from the horn mounts to the first ridge.
Now your done with the cardboard!
Step 11: Horns
I got lucky and found these Styrofoam pieces in an old car seat.
Most cant find these, so I'll update this when i can make cardboard horns its fairly easy, bonus points if you can make them yourself.
Step 12: Attaching Horns
Put glue on the top of the horns and put it in its mount.
Quickly adjust the horns if needed, the glue can set pretty fast.
Step 13: Begin Taping
then go over the ridges.
*(side note) when coating with duct tape use thin strips (normal strips torn in half) around the edges, then cover the larger areas with normal size strips.
Step 16: Horns
Step 17: Tape the Insides
Now look around the whole helmet to see if there's any cardboard showing, if so, more duct tape!