EDIT:
I forgot to mention this, but I got the idea from this guy: Eric Testroete, who apparently got it from someone else but I saw his so I'm gonna stay with that :P
EDIT 2:
Someone pointed out that there was already an instructable for this so I'll link him on here as well: Real Life Big Head Mode
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Signing UpStep 1: Ingredients
Items needed:
3D program - modeling and able to export OBJ file
Pepakura - to change the OBJ file into cuttable paper images
100 lb cardstock - needs thick paper so that it'll hold the shape
Sharp scissors and Xacto Knife - for cutting paper... be careful
Super Glue/Hot Glue Gun/Double stick tape - to put all the pieces together
Optional items:
Resin or Casting Plastic - to harden the helmet
Foam Padding











































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Halo 1 helmet and X-wing helmet later, I wish I knew that then.
http://www.flickr.com/photos/dutchct/sets/72157622591528101/
which inspired me to make it... I'm gonna go do that now...
That should keep for years. I could be wrong but heck give it a try. Also you could print out on regular paper and glue onto cardstock. BUT copy centers are very reasonable so one must consider them, versus your cost.
great instructable