Pepakura Rocketeer Helmet

This is my first experience with Pepakura, and I wanted to build a Rocketeer Helmet.

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
super glue
fiberglass and resin
Bondo
primer
sandpaper
palm sander
detail sander
foam core
Magic Sculpt
Gold Rub and Buff
1/8" tinted acrylic
E6000 glue

Step 1:

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.

Comments

[Drillbit]

If I may did you create the helmet file from scratch or did you pull it from a forum? If a forum could you pm me with it. I've been looking for this helmet for a long time.

Thank you

[monkeywork]

Sure thing!

[jarikcbol]

Awesome 'Ible! I always loved the movie. Quick tip for future projects. Instead of using Bondo, which, as you said, stinks to high heaven, look at using a product called Durhams Water Putty. In projects like this, it will work just as well as Bondo, but does not have the awful smell.

[monkeywork]

I'll look for that! I used Bondo, because that's what I had laying around. (I'm not cheap, I'm thrifty!) But I'll search it out!

[PS118]

Wait. Rocketeer's helmet... Cap'n America's shield... lightsaber...
You, sir, are officially indestructible! :)

I love this!!!

One other option for the faux welding. I remember seeing in an issue of Woodsmith magazine where they made a fake metal clock out of wood. (Sorry, I can't find a pic online anywhere.) To get the welding look they just ran a bead of regular painters' caulk (don't smooth it, of course) and painted over it.

[monkeywork]

Right now I'm working on a District 9 inspired Nerf. My Halloween costume is going to be a hot mess.

[craigferguson]

sweeet man! nice job!

[monkeywork]

Thank you!

[Penolopy Bulnick]

That looks amazing! Now I want to watch the movie again :)

[monkeywork]

I recently re-watched it, it's a fun movie. Seeing the GeeBee airplane featured was nice too.

[wwhitt]

Can you please elaborate more on this step I was confused reading it

[monkeywork]

Sure thing, with autobody filler, aka Bondo, you mix up a small batch, spread it over the helmet and let it harden. From there you sand it down to smooth it out. The goal is to fill in all the holes and smooth over all the bumps of the paper to create a smooth helmet verses one that has the angles of the paper.

It's time consuming, as you have to wait for everything to dry. If you don't wait and start sanding too soon, the filler will just load up the sandpaper and frustrate you. I move on to other projects, (like work!) and let it fully harden up before sanding.

This is where your sculpting skills come into play, creating a smooth surface from a faceted one.

[jawasan]

very nice job, like the welds!