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. 



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Step 1: 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
-Printer
-Pep files(halo pep files)   
-pepakura viewer 3!


http://www.tamasoft.co.jp/pepakura-en/
 http://halocostuming.wikia.com/wiki/Pepakura_File_Index

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.

Comments

[4lifenerdfighter]

Any recommendation on what resin to use?

[budhaztm]

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

[4lifenerdfighter]

And how do you get the nasty acetone out?

[KemikalzAreFun]

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!!

[budhaztm]

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

[renscan2]

yep, not alot is needed.

[halofreak27]

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

[mattchu247]

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 [e-mail] 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]

nice man

[Jerod the guy]

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

[mccannip]

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

[darkscourge22]

what did you make the visor from

[renscan2]

I bought one.

[zbarton1]

where did you buy the visor?

[Master-Chief]

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

[bdavis23]

how do u print it.

[globogym]

never mind I figured it out:)

[globogym]

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]

hello for everybody

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


Regards

[nutupww]

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]

Is there a way to get pepakura for mac?

[just pick a name]

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 www.winehq.org

[everydayastartes]

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.

[renscan2]

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.
-Peace

[darkscourge22]

and also, can you see through the visor?

[renscan2]

Do I even need to answer?

[renscan2]

Vote for me :)

[sk19]

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

[renscan2]

yes

[sk19]

did u use regular paint or spray paint

[renscan2]

Spray paint

[wldmnky42]

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?

[renscan2]

Hey,
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]

srry and idont know how to put the pictures on the pepakura

[renscan2]

Make sure your files are correct and then open it in pep.

[sk19]

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

[renscan2]

What is an eva helmet?
is that from wall-e or something?

[sk19]

thats from halo its the helmet that emile wears in halo reach

[wldmnky42]

you know what, just realised the shape wont match if i harden then connect. i'll connect it and upload a pic, then progress from there.

[renscan2]

That may be a good idea, I don't know what a halo rogue is but If the visor is difficult then that may be a smart thing to do.