Introduction: Fallout 2 Veterans Helmet Build

Picture of Fallout 2 Veterans Helmet Build

Ever since I read about pepakura helmets, I wanted to build my own. My first attempt was the classic master chief helmet, sadly I was not able to complete it since the cardboard material, I got was to thin and flimsy. My 2nd attempt was an Ironman helmet. Although I was able to complete it, I did not like the way it turned out. So I gave up on pepakura until I came across this link:

The problem I had with pepakura, is that I always end up with a flimsy looking build. I was not willing to work with fiberglass as we have kids running around the house. what I needed was something to make it solid enough to wear but does not require any special handling procedure or equipment. I read about plaster and glue sticks as alternatives and those are materials I was happy to work with

So here is my 3rd Pepakura build...Fallout 2 veterans helmet.


My friend updated this build and put up an antenna and LED lights. He also started wearing this together with the vest. :)

Step 1: Materials:

Picture of Materials:

Stick with the basics: Pepakura files are available here:

or you can search on the web for other versions.

  1. cardboards
  2. x-acto knife
  3. glue gun / glue sticks (a lot of it)
  4. plaster of paris
  5. foam
  6. watercolor *optional
  7. spray paint (primer, clear coat, metalic silver and flat black)
  8. plastic sheet for the mask lens
  9. a shower hose or BX cable for the oxygen hose that will stick out of the gas mask.
  10. elmers glue
  11. instant glue

as with any pepakura builds, you print the files and cut them up, fold and stick them together. I found out that it's always easier to pick a portion of the build you want to start at first, cut those and assemble it. rather than cutting everything up and looking for the numbers that match. You can use elmers glue, instant glue or gluegun during assembly. I opted for the glue gun since it made the joints more rigid and stable. Although you really need to work fast with a glue gun.

Step 2: Fitting the Lens and Reinforcing the Joints

Picture of Fitting the Lens and Reinforcing the Joints

After everything has been assembled. It's time to make the lenses. I used an old red plastic sheet cover from a ring binded document I have, any clear plastic would also do. I used this as it was easier to cut. Dont glue it up yet, just see if it fits.

Time to get those glue sticks. what I did was go over every joint of the helmet (on the inside ofcourse) and fill every gap with the glue gun. This made the helmet sturdy enough to be worn. Another method suggested that you melt the glue sticks and pour it on the inside of the helmet. I'm sure that method would be better but as said we got kids running all over and having melted plastic is never a good idea.

You can now start putting plaster on the helmet. I was not able to get a photo of it, since working with plaster meant mixing and splattering. hard to press on a camera with plaster on your fingers. I also put elmers glue on the plaster mixture so it will dry faster.

After drying you need to sand off the rough edges.

Step 3: Spray on the Primer

Picture of Spray on the Primer

Make sure the plaster is really dry. Go on and spray paint the whole thing atleast 2 coats. then go back and sand it off. You can either wait until you finished painting the helmet with flat balack before putting the foams in so it will fit on your head or put them on before you spray paint with flat black. I inserted and glued the foams before as flat black application since I wanted everything painted black.

Step 4: Accessorize

Picture of Accessorize

I got a lot of electronic junk, including old webcams and old cellular phones. took anything that was light enough to glue on the helmet. The blood red is actually water color (poster paint). I made a template for the logo and just spray painted using the silver paint. I spray painted the red poster color with clear coat just to keep it from fading. Yes, finally you can put on the lens. There you have it. :) Gave this to a friend who was into cosplay.


rainingfiction (author)2017-04-02


Archer2500 (author)2016-11-05

hey again-

Sorry to bother you with so many questions. Finishing and merging the mask and tail parts together, I don't seem to understand how to wear it.

riocruz (author)Archer25002016-11-06

This build comes in 2 parts. One is the helmet and the other is the mask. You wear the mask first like a regular face mask and then simply put on the helmet like a hat. In my case I made some adjustments on the mask so it will my face. You may use velcro or just a string to tie it in place. As for the helmet you can put foam paddings like I did so it will sit perfectly on my head.

Archer2500 (author)riocruz2016-11-06

what is the tail part attached to?

riocruz (author)Archer25002016-11-08

each side is attached to each other. it's up to you if you want to trim it shorter or extend it a bit so you can slip it on your head. Or you can put velcro on each side so you can open it up and fasten it when wearing it.

Archer2500 (author)riocruz2016-11-20

ah, alright. Thanks so much for the help, will probably upload photos if project is satisfactory.

Archer2500 (author)2016-11-03

What is the curved piece under the left floodlight of the helmet?

riocruz (author)Archer25002016-11-03

it's just part of the pepakura assembly.

Archer2500 (author)riocruz2016-11-03

The linked files don't seem to have it

riocruz (author)Archer25002016-11-03

Someone made a comment before that the file on site was change by the author. I have uploaded file I used for this build above. That is the "Fallout NV NCR Veteran Ranger Helm by Hugh.pdo" this is part of the mic assembly.

Archer2500 (author)2016-10-28

Hello, what was the paper used, what solution was used for the tissues and what were the dimensions of this helmet?

riocruz (author)Archer25002016-10-29

Paper for what? for the helmet structure or the tissues? ordinary paper towels would be ideal as they don't break off easily. if your asking for the paper for the pepakura printing I used card boards like that of folders.

Archer2500 (author)riocruz2016-10-29

aight, thanks

Archer2500 (author)2016-10-28

Oh, and since the pepakura is in multiple parts, how do you get the proportions?

riocruz (author)Archer25002016-10-28

Scaling in pepakura will be done for the whole file. So if you're working on a helmet the scale will be applied for all the parts in that file. youtube has a lot of tutorials on how to do this. here is a link to one of them

Archer2500 (author)riocruz2016-10-29

thanks mate

Gamesmasher23 (author)2016-10-22

I'm having an issue where it is only printing the numbers and not the lines. Do you know of a way to fix this issue? Does it have to do with the absence of most of the lines when viewing it in any other software than Pepakura?

riocruz (author)Gamesmasher232016-10-22

have a look at the print settings in pepakura, you can select vector so the lines will be more visible during printing. You can also check your printer settings, print in monochrome and adjust contrast. if those doesn't help check out the pdf files above and print them out normally. hope this helps.

riocruz made it! (author)riocruz2016-10-23

just in case, here are my print settings on my pepakura viewer.

Gamesmasher23 (author)riocruz2016-10-24

Thank You.

ChristianM227 (author)2016-10-18

Hey there bud! I am working on this right now. I was wondering what kind of plaster you recommended? I have a pack of gauze plasterstrips, but I am not so sure about that.

riocruz (author)ChristianM2272016-10-18

I used plaster of paris on this build. If I had access to that, I would have definitely tried using that. As this would probably saved a lot of time.

riocruz (author)2016-10-09

Ok, so I finally got around uploading a copy of the old pep file I used for this project. The file link above has been updated by the owner. Both files are property of the guy in the link.

Reaper40 (author)2016-09-23

I mean like the seperate pieces before you glue at all.

riocruz (author)Reaper402016-09-24

the pep files are in the link provided or alternately I could send you the files I've used for this build. I was informed that the files in the link were updated for more detailed construction. The pep files are printed in the same scale, so i don't think you need to worry if it will fit the other pieces. the files are in my email, I'm too darn lazy to upload them anywhere else. So drop me a message with your email so I can send it to you.

Reaper40 (author)2016-09-23

Hey so I looked at a picture of one of these that laid out all the different cardboard pieces. But it doesn't show the measurements for any of them. So I'm afraid of messing up one measurement and not realizing it before it's too late. Do you know what the measurements are or do you have a file that shows them?

MuchPiggles (author)2016-09-20

I also could use the original files for the pieces. Sorry.

riocruz (author)MuchPiggles2016-09-20

message me your email and i'll send it to you.

MuchPiggles (author)2016-09-20

What is the parts used on step 4 and how was it made?

riocruz (author)MuchPiggles2016-09-20

They are just a bunch of broken boards of cellphones and webcam parts. I used instant glue to stick it on the helmet. This part is optional as you can just paint it as you like. I wanted to make the helmet look worn so I added the broken bits and pieces.

MoistBurrito (author)2016-06-22

One more thing, what's the tissue for?

riocruz (author)MoistBurrito2016-06-22

The tissue was used as a reinforcing layer. like paper is to a paper mache. It dries a lot faster than paper mache depending on the binding mixture. I used this in combination with the plaster to harden the helmet to make more rigid and maintain the shape.

MoistBurrito (author)2016-06-21

I was wondering the same thing as Mr wil30n. Help?

riocruz (author)MoistBurrito2016-06-21

Send me a message with your email add and I'll send you the files. :) Uploading the file somewhere and later finding out it is broken is so frustrating, so this way I'm sure I can help out.

MoistBurrito (author)riocruz2016-06-21

jakepward AT gmail DOT com, did it this way to avoid spam

ALSO: In the parts list you said cardboard, not sure what that is used for in the build, but in the comments you said cardstock, likely for the pepakura. So what did you use for it?

riocruz (author)MoistBurrito2016-06-21

Cardboards, I used cardboards for this build. I put card stock in the comments as I thought it would be easier for others to find those instead. I had to cut cardboards into size to fit the printer, this is a tedious process and I would like to spare anyone this step. Try to use the thickest one you can find and that your printer can handle. :) btw I love your user name. :)

MoistBurrito (author)riocruz2016-06-21

Thanks for the info. =)

mrwil30n (author)2016-06-17

I built the mask and helmet but havent started the back of the mask yet, the person who created the original pep files has updated them to be more realistic which means MANY more pieces than the original, I dont care about the look of the back of the mask and so i wish to use the original pep files yet cannot find them there any chance you still have the files and could send them to me.

Any help is appreciated

riocruz (author)mrwil30n2016-06-18

Luckily, someone asked me for this before. yes, I still have the original pdo and a pdf for this. drop me a message so i can send it via email.

riocruz (author)riocruz2016-06-19

email sent. :) have fun.

DonutTheGREAT (author)2016-06-01

How much did this cost?

riocruz (author)DonutTheGREAT2016-06-01

Here is my parts list. I have converted the currency in US dollars. I'm sure you can get these materials at a much cheaper price. in total this build was under $20.

Elmer's glue 2 bottles $1.59
Glue sticks (100pcs) $2.27 (Don't worry I was not able to use them all)
Plaster of Paris $0.68
Spray paint (Clear) $2.75
Spray paint (black) $2.75
Spray paint (silver) $2.27
Spray paint (primer gray) $4.09
Shower hose $1.13
Assorted sand paper $0.90

Total cost $18.45

Things I got for free:

Red water color
Red plastic for lenses
Card stock
Tissue paper
Electronic Junk
Pep file & printer

Thanks for viewing. :)

ethanm17 (author)2015-11-12

how big is the diameter inside (in cm please)

ethanm17 (author)ethanm172015-11-12

and do you need a special printer to print out the peparuka thing??

riocruz (author)ethanm172015-11-12

no special printer needed to print pep files, you just need the pepakura viewer which you can download here: it's free.

I have not really measured the helmet for size, but I approximate this to be roughly around 7 to 8 inches in diameter. I remember putting some foam to snugly fit it on my head. However, the pep viewer can also be used to adjust the scale of the helmet. Hope this helps and thanks for the comment. :)

ethanm17 (author)riocruz2015-11-15


ashleyjlong (author)2015-11-08

Nicely done! I really like the paint job. My boyfriend made one of these a few years ago for Comic Con and installed an old computer fan inside to circulate air and prevent the lenses from fogging up. Definitely made it more tolerable to wear for extended periods.

riocruz (author)ashleyjlong2015-11-09

Thanks! Luckilly my friend doesnt have to wear this longer than he needs to. he just wears them whenever cameras are pointing at him. :) thanks again for the comment.

LoganW8 (author)2015-10-07

How long did it take you to make this?

About This Instructable




Bio: just a guy who likes robots, sci-fi, computers and prop making on a very tight budget.
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