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Papier Mache Master Chief Helmet

Papier Mache Master Chief Helmet
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Just about every Halo armour build out there uses the resin/fibreglass method.  Here's an alternative method of constructing a sturdy armour, for those like me who:

a) lack a large enough garage or home workshop to safely apply resin and fibreglass, and
b) are sensitive to the chemicals used in resin and fibreglass

This method uses papier mache, which, if done properly, gives something rock solid (or more so than cardboard, anyway).

Materials needed:
For the helmet:
Lots of paper, 70-80 gsm (eg normal copy paper and brown kraft paper)
A roll of paper backed foil wrap
Masking tape
Spray adhesive
White PVA glue, 1 litre
Cellulose wall filler (or spackling paste)
Yellow cellophane paper
Semitransparent silver cellophane paper (or silver mylar)
One hot laminate pocket (A4 or letter)
One plastic washing machine hose

For the helmet lights:
4 green LEDs, 10 mm
One ferrite toroid
Insulated wire
One npn transistor (2N2222, 2N3904, or equivalent)
One 1k resistor
One switch
One 1.5V battery holder
One 1.5V battery

Paints:
Green acrylic paint
Black acrylic paint

Total cost of the above is $50 or less, depending on your scrounging skills.

Tools needed:
A sharp blade for cutting paper
Scissors
Cutting mat
Containers to hold glue and pulp
Spatula
Solder gun
Hot laminator
Glue gun
Drill (optional)
Computer
Printer
Paintbrushes (if you're not using spray paint)



 
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Step 1Get the pepakura files

First, find a pepakura file for the helmet.  The one I used was from gamescanner.org, but it looks like the file is no longer available.

But there's more here:
http://halocostuming.wikia.com/wiki/Pepakura_File_Index

Check out the tutorials on how to scale the helmet (if necessary), then print the pieces on normal copy paper.

Don't cut them out yet though!


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4 comments
Feb 13, 2011. 5:34 PMfelixneko7 says:
how well can you see through the visor?
Dec 20, 2010. 12:03 PMemoxD123 says:
omz! that is amazing hahaha i loves it!!! XD
Oct 18, 2010. 7:51 PMwraith109 says:
It looks pretty good overall however, if you really want to make it pop spend a little more time smoothing and sanding to get that realistic look.

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