Always wanted to make a helmet from Halo, Daft Punk, Gears of Wars, or any other iconic character that you like a lot? This instructable is for you! (And it works for armor too!)
Obs: This is my first instructable, and if there is any grammar mistake, sorry, english isn't my first language! and the .PDO for Guy's Helmet is in step 2.
Obs²: Gloves tutorial are now on page 10!
Step 1: Materials
FIRST: If you don't have patience, just leave, you need A LOT OF PATIENCE!
*Pepakura Viewer 3
*.PDO file of your desired helmet (.PDO for Guy's Helmet is in step 2)
*Paper (Of any kind, but I use cardstock)
*Scissor or X-acto knife
*Fiberglass and Fiberglass resin
*Bondo (Car Body Filler)
Step 2: Paper model!
Print out your paper template in Pepakura Viewer, cut out and start gluing everything in place! (How to do this is theme for another instructable)
Here's a tip for gluing the parts togheter: http://www.instructables.com/id/Pepakura-armor-making-quick-tip/
Update: I've uploaded the pepakura files for people that wants to make the same helmet!
Step 3: Fiberglass!
Apply your fiberglass mat or cloth and resin over your paper helmet or armor, let it dry and it will be hard as a rock!
(TIP: Fiberglass the inside, not the outside as I did)
Step 4: Bondo!
Apply bondo to the places you need to get smooth! (Normally round or curved places, straight parts don't need to be "bondo'ed")
Step 5: Sanding! (And lots of it)
Take your various grit sandpaper, and start sanding from 150 grit, until 600 or even 700 grit! Get everything nice and smooth or you may regret it in the future!
Step 6: Painting!
Take your spray paint and put a layer of primer on this helmet! Sand off any imprefection and primer again if needed! Then, your final color and a layer of clear laquer!
Step 7: Visor!
Next you need to add a vior, and you can buy plastic, plexiglass, a motorcycle helmet visor, but in my case I needed to vaccumform a visor! And attach it with superglue or hot melt glue!