Introduction: How to Make a Halo Helmet Using Pepakura!

Picture of How to Make a Halo Helmet Using Pepakura!

I saw a bunch of tutorials but many were incomplete or low detailed. So, here I have my first, er second Halo helmet, Please criticize all you want, I don't care if this is my first instructable though constructive criticism will help. 


Step 1: Supplies

Picture of Supplies

You will need multiple supplies and a BUNCH of time, A BUNCH!!!
This may cost around $20-$50 depending on how much you buy.
You will need
-Card stock
-Paper Craft glue. Elmer's  is the kind I use. Try not to use any other glue as this type will bond paper better.
-x-acto knife/paper craft scissors (DO NOT USE REGULAR/SAFETY SCISSORS)
-cutting board (if you don't want your find wood table to have cut marks)
-Fiberglass Resin
-Bondo Bondo
-dust masks 
-some useless paintbrushes
-useless credit card
-Pep files(halo pep files)   
-pepakura viewer 3!

all the files you will need are up here. If you don't know what pepakura is, it is basically a program that converts a 3D object into 2D so you can cut and glue it after printing
This is the easiest way to make a halo helmet, I might add some more supplies later on
so read through carefully.

Step 2: Cutting, Gluing, and Papercrafting

Picture of Cutting, Gluing, and Papercrafting

Now after you have gone and downloaded the files, open them up in pepakura
*they should be .pdo files

now print them out and cut and glue accordingly to the pictures, In pepakura if you click on a piece you can see where that piece connects.
Turn on 
Show edge ID
then just connect to the according piece.
The dashed lines like this ------ mean to mountain fold
the dash dot lines like this  dash dot dash dot ( couldn't find a dot thing)
mean to valley fold.

now cut and glue.

Step 3: Fiberglass Resin.

Picture of Fiberglass Resin.

This part is pretty toxic so WEAR MASK AND GLOVES! I use latex gloves from walmart but any gloves will do as long as you can throw them out!
Mix the fiberglass resin in a container according to the instructions and mix evenly.
So, after you have covered everything, make sure your in a well ventilated area... OBVIOUS

or else it will harm your braincells.

Just apply and even coat to the outside and wait to dry.
then apply and even coat to the inside and wait to dry.

This should take a few hours to dry so don't rush it.
after it dries is should be pretty hard and smell funny thats okay because we're gonna
put something that smells even funnier onto it C:
Washing it with water will not get resin out.

Step 4: Bondo

Picture of Bondo

Sorry guys I didn't take any pics for this so i'm going to use my iron man pics. The only thing about the iron man pics is I put WAY too much bondo on it. Just apply a thin layer and make sure it is smooth.
You need
-used credit card
-containers to hold it.


Sanding. This is a pretty simple but it is really really useful
Probably don't have to explain this one.

Step 6: Painting and Battle Weathering.

Picture of Painting and Battle Weathering.

Spray paints are usually a good choice.
I used
-little bit of gold but thats because I ran out of silver.
Spray on a layer of flat black primer.
next spray on a layer of silver

now to do the battle marks and weathering.
Its hard to explain so..
watch these videos. It is not me but he does a FANTASTIC JOB. I commend him.
Watch his videos, they are all incredibly cool

after you put your weathering scratches on
spray a layer of red paint.
now do what he does in the video and carefully scrape off the vaseline.
you will be able to see  the silver underneath.
to make more scratches take a piece of sandpaper and rub it against the helmet.
also spray some paint onto a paint brush and gently apply silver paint to edges.

next we begin the process of distressing
to distress, all you need is a
-useless towel rag
-black paint
spray your black paint and quickly wipe it away from the helmet.

in picture 1 you can tell where I distressed.

Step 7: Finishing Up.

Picture of Finishing Up.

Now you will have a great looking helmet!
next you need to buy a cheap motorcycle visor
I purchased mine from eBay for approx. $25 shipping included.
just hot glue your visor in and WAH LA!

oops, forgot a step.
buy some cheap sponges and glue them into your helmet so your head doesn't wobble around.

Step 8: Conclusion

Picture of Conclusion

This is a great project and looks great.
It is pretty time consuming so make sure you have a week of spare time
I did this over summer break.
Don't buy a too expensive visor.
I spent around $70 maybe
How much did you spend?
I want to see your pics!

So long and happy crafting!


Tesla871 (author)2017-10-28

Hey do you think this would be possible with a thinner type of cardboard?

naiomii (author)2014-07-21

What blueprint did you download to make the helmet shown? Im new to pepakura and I've already downloaded a helmet but it looks MUCH more complicated than what you have shown.

Tesla871 (author)naiomii2017-10-28


leoishungry (author)naiomii2014-07-21

Hi Naiomii,

I made this tutorial a long time ago so I don't quite remember what blueprint I used to make it. I do remember it was from a website that contained a bunch of other Halo pepakuras. The process of cutting and gluing is definitely the most time consuming part of the build but also isn't too complicated. When you print, you can set the tabs to have tab numbers so you can easily piece them together. It might take you a week to put everything together. Hope this is helpful. Sorry I haven't been on Instructables for a LONG time. :-)

mrsheapard034 (author)2017-10-03

glad I know now might do an entire armor set not just the helmet how much would that cost though

MuchPiggles (author)2016-09-20

This is probably way late but I have a question. Is plaster of paris or fiberglass resin better for pepakura. I saw a different instructable and he used plaster but you used the resin.

MuchPiggles (author)MuchPiggles2016-09-20

Also what kind of Bondo did you use?

ammunitio (author)2016-02-18

Any thing new ur making

TrucyW (author)2014-08-31

What's it like breathing in that?

brandondime (author)2014-06-18

Im pretty new to this, im designing a Dark Knight mask and was kinda curious, do you use both bondo body filler and putty or just either one? i already have the fiberglass resin, just was kinda questioning this part

CrystalB01 (author)2013-12-25

Real cool ! For he record I will be making this soon !

astyzthewise (author)2013-09-30

what color red exactly?

KemikalzAreFun (author)2013-03-22

Very nice! A bit of constructive criticism. When you use your bondo make sure you take your time, sand inbetween layers (thin layers make your work go faster) and keep repeating this processes over and over until your helmet/mask is perfectly smooth, then sand with FINE sand paper.
Takes more time but the end result is VERY satisfying. Good job though!!

Thank you! I haven't done pepakura or bondo since this last project as I've fallen kind of out of it. This was sort of my first major pepakura and I was relatively inexperienced. I also feel kind of stupid going back and looking at how I wrote things haha. I was the child who wanted everything to be done as quickly as possible so I could admire my end result. Appreciate the criticism despite my late reply eek!

4lifenerdfighter (author)2013-04-25

Any recommendation on what resin to use?

I think mine was elmers but i'm not sure. It's been a long time but I remember it was a blue square bottle-ish thing.

Wolfbane221 (author)2013-09-29

I like your pep instructable. I finished putting my first pep together today of a halo smg because I thought it would be easier... I might have been way wrong. All those tiny *#%*%+ folds took forever! are the helmets like that too? Anyway, I'm waiting for the resin to cure and it probably took me 6hrs to put together. I spent 90$ up front to have a good amount of resin/bondo/paint for multiple projects. Why don't you use fiberglass sheets as reinforcement with the resin? I also left that out of my resin curing but wondered if you had a specific reason for it. I am looking forward to painting and weathering mine.. it looks fun. Hopefully the smg turns out good and then I'll post pics!

leoishungry (author)Wolfbane2212013-09-30

So I totally forgot about my instructables but just came back to see how it was haha.

In hindsight, I probably should have used fiberglass mat or sheets. Afterwards my helmet started to get all bendy and that wasn't good. My reason was I didn't quite understand it yet and it was kind of expensive so I decided against it haha. Yeah the pepakura part was a pain. $90 worth of resin and bondo should last you quite a while and good for you that you've completed it. Painting is the funnest part! Definitely post some pics when you are done!

I haven't used instructables in forever so forgive some of my immature tendencies in the yellow box notes.

budhaztm (author)2012-08-24

Water won't get the resin off but sometimes acetone will. Just be careful with that acetone, it's nasty

And how do you get the nasty acetone out?

budhaztm (author)2013-01-07

So how much bondo would you say to use? Would one quart be plenty?

leoishungry (author)budhaztm2013-03-13

yep, not alot is needed.

halofreak27 (author)2013-01-05

awesome!!!!!! i made my own its epic

mattchu247 (author)2012-09-17

U did an amazing job on this
i know this is about 2 years late looking at everything Man i was trying to print out the helmet the other week and the numbers on the paper were totally put together so close over topping them so i couldnt use it
how do you put the scale and width and all that because i tryed putting in numbers somone put in theres and it totally changed them so thats why it printed out diffrent and over toping it
if u could email me at that would be amazing
thanks also i bought a morphsuit from amazon it came from the uk its a tuxedo one so i think it wud be koool and funny with a halo helmet

panzer101 (author)2012-03-03

nice man

Jerod the guy (author)2011-12-24

you said the supplies cost around 50 bucks is that with/out printer?

mccannip (author)2011-12-20

those sponges are japanese.i'm japanese and i can read what it says...

darkscourge22 (author)2010-11-21

what did you make the visor from

I bought one.

zbarton1 (author)leoishungry2011-09-04

where did you buy the visor?

Master-Chief (author)zbarton12011-11-29

You can get them on ebay or amazon, if you want links to the gold shield that fits these style helmets visit: and look in the materials section. In the attached pic it shows what they look like in the halo helmets.

bdavis23 (author)2011-08-06

how do u print it.

globogym (author)2011-08-02

never mind I figured it out:)

globogym (author)2011-08-02

I cannot for the life of me figure out pepkura. Could someone email me screenshots of their pepkura or attach something so i could still do this project? It would be so greatly appreciated:)<3

ahmed1411 (author)2011-07-07

hello for everybody

I need help .I need to know how i can make safety helemt by sample tools


nutupww (author)2011-07-03

Yea, every time I try to download the file it tries to come up in a PDF file. I have Pepakura Viewer downloaded and everything. Help?

William930 (author)2011-01-25

Is there a way to get pepakura for mac?

I use Ubuntu linux, and it works somewhat under WINE. I a friend uses a version of WINE on his Mac, but he's quite computer savvy, so ymmv. WINE stands for Wine Is Not An Emulator. More info can be found at

everydayastartes (author)2010-12-03

hey hope you're still on the thread I'm preparing to build my own W40k outfit with some pep files and i was curious how long it took you to build your helmet and about the amount of time a day you put into it? I'm hoping to get my suit ready by june for akon in dallas,tx. thanks.

Hey! It's good to see people still intrested in this.
Pepakura will take most of your time.
The pep for the helmet took about 1 week maybe 2-3 hours a day and the rest of the helmet to finish it and harden it took about a week also but with lesser commitment. I think you will find it easier with each failure you make. I recommend trying something easy to pep and then going into the hard stuff.
Good luck with your outfit and yes, you will need all the time from here to june if you can make it fast enough.

darkscourge22 (author)2010-11-22

and also, can you see through the visor?

Do I even need to answer?

leoishungry (author)2010-11-09

Vote for me :)

sk19 (author)2010-10-30

is that card stock u cut out in the 6th pic???

leoishungry (author)sk192010-10-31


sk19 (author)2010-10-30

did u use regular paint or spray paint

leoishungry (author)sk192010-10-31

Spray paint

wldmnky42 (author)2010-10-14

okay, so I have the cutting and gluing done for the Rogue Helmet (actually came out pretty nice).

btw, how much would you sell one of these for? i've looked online, and full suits that actually look pretty good cost somewhere between $800-$1000. so what would you sell, for example, the helmet you had made for?

leoishungry (author)wldmnky422010-10-14

First off, I wanna see your pics. :) they must look great
Second, your right about the cost of these, majorly expensive but a helmet might go for $100-$200 because of costs of supplies and labor, mine I might sell for $150 because its not the best but no the worst and I spent about $70 bucks on supplies. :P

sk19 (author)leoishungry2010-10-23

hi i downloaded the pepakura thing and im trying to make an EVA helmet and im trying to put the pictures (instructions) on how to make the helmet

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