This is my first experience with Pepakura, and I wanted to build a Rocketeer Helmet.
I have the pepakura file on my website: monksvoice.com/Rocketeer
So, I downloaded Pepakura and ran it on Virtual Box on my Mac. The helmet file is easy enough to find. I didn't do any modifications to the file itself, I just printed it out on some matte paper and started cutting pieces out.
Here's a list of materials:
matte paper or any heavy stock
razor knife and scissors
fiberglass and resin
Gold Rub and Buff
1/8" tinted acrylic
Lots of pieces! This was actually kid of fun. I carefully cut out each piece and attempted to keep the numbers together, so I wouldn't have to go searching for them later.
That was wishful thinking. Searching for the attaching number and tab was a puzzle! I used superglue to bond the paper together.
It slowly begins to take shape!
And here it is! All it is so far is superglue and paper. The air vents on the top took some figuring out, but with enough tape and glue, they held and were symmetrical.
So I mixed up a batch of resin to coat the outside and inside to give it some rigidity. No fiberglass at this point. Just let the resin soak into the paper and let it sit overnight.
The next day, I mixed up more resin and added a layer of fiberglass to the inside of the helmet. At this point, while you can still see the original paper lines, cut out the fiberglass to the paper and cut out the holes for the mouth. Get them as clean and accurate as you can, because once you loose track of the holes in the paper... you're on your own. (ask me how I know...)
The Pepakura will print out the fin on the top, but it's a little flimsy, so I replicated it in 1/8" foam core and did the resin treatment to that as well.