Hello, Here I will show you how to make your very own Bandit thug Helmet from borderlands for a convention or Halloween or just to display. When making this project you will need to make sure you print the pieces out to a scale that is correct for you. In the file The neck pieces do not need to be assembled if you are going to be making this as an actual helmet to wear.

If you need help with using the resin/bodyfiller/fiberglass ask a parent or someone responsible to help. It can be a very dangerous medium to work with.

What you will need:
X-Acto Knife and a pack or two of fresh #11 Blades (USE WITH CAUTION, YOU CAN LOSE A FINGER VERY FAST!)
110lb Cardstock
Pepakura - HERE (a program for unfolding 3D models to be printed out on paper and re-assembled)
Bandit Thug File - HERE
 Various bits of plastic, colored foam sheets and styrene for the mouth piece and other details
2 Flashlight Ends with lenses
Paints and brushes (I used acrylics)
Body Filler
Fiberglass with proper mask if you want to go full safety (NOT the same mask as resin)
Resin with proper mask for full safety (NOT the same mask as fiberglass)
Dremel or other rotory tool with proper cutting attachments
Hot Glue and Glue Gun

Here's a screenshot of the game showing the helmet we will be making HERE

Step 1: Step 1

Open the file up in Pepakura and resize it accordingly. It will not be easy and you will probably not get it on the first try. I would upload a pre-scaled file for you but my pc crashed and the file was unfortunately lost. You will probably need the pay version to re-scale or edit the file but I'm not sure because I own the pay version.

Once you get it to the correct size for your head then you assemble the helmet using superglue as it will make this process go a lot faster. On the red lines you fold a mountain "^" and on the blue lines you fold a valley "V". cut on dotted lines.
<p>Looks like a smiley Face xD</p>
You think Polyurethane would work well as a replacement for the resin?
Congratulations on being a finalist in the Halloween contest!!! Can&rsquo;t wait to see if you win! Good luck!
Thank you :) I hope it's my time to place in a contest, So many great projects!
Hey Tim, mask looks realistic, awesome job as always, got you a vote. Keep plugging away. :)
Ever seen The Legend of Korra? This looks almost exactly like the equalists' mask!
That is so neat - very very very close to the real thing!
Thank you very much! It's surprisingly easy to complete with just some common sense and patience. This was my first attempt at anything like this and I was REALLY happy with the outcome. :)
Hey My friends and I really love this project we are just wondering if you'll make a guide for a Bandit Raider-(Steve the bandit), Killer and Psycho mask. I know it's a lot to ask but it would be really awesome.
Thank you for the comments folks. I'm sorry I haven't been very responsive, I just got internet turned back on today because our small town was destroyed by tornadoes on march 2nd/3rd.<br><br>@ anibioman, you are 100% correct on using some black and a small brush over a sharpie but I was going for the inked in comic look from the game. even though you may not be familiar with borderlands you still do bring a valid point in getting a stronger opaque look and I recommend anyone else try your suggestion as it will have a very different effect as opposed to what I was going for. :)
hi im not familiar with border lands but this looked like good steps for making other helmets and armor i think it came out really good only problem i have with it is in this step you used sharpie i just think sharpie tends to not work as well as a small brush and black acrylic for me sharpie tends to streak a ton and isnt as opaque as compared to paint.
This is actually a very accurate and amazing structure and I love Borderlands. I may end up creating a similar structure for cons and such. I love it and continue the good work! <br><br>Borderlands 2 comes out soon, prepare for the fan comments here XD
This is really well done! I wish I could get my hands on some 110lb cardstock and make myself one :D

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