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)
Remove these ads by
Signing UpStep 1Get the pepakura files
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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