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
super glue
fiberglass and resin
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.
That did it. Odd because I clicked on the link and got the error. Must've been a server hiccup. It works now.
Where can I get a copy of the pdf?
<p>I just put one on my server at <a href="http://www.monksvoice.com/Rocketeer" rel="nofollow"> www.monksvoice.com/Rocketeer</a></p><p>Good Luck!</p>
<p>404 error. File not found.</p>
<p>they're there. click the link or make sure you type it with the capital &quot;R&quot; on Rocketeer.</p>
<p>This is what i was looking for. I am going to build this for my Rocketeer halloween costume. I have all the costume parts except the helmet and jetpack. But i have a question, what size is this helmet?</p><p>Thanks!</p>
<p>My hat size is 7.5, This is how it fits on me.</p>
<p>monkeywork, thank you so much. I did make the helmet out of paper and it's a little too big. So me and my dad are going to build it out of sheet metal and get padding for the inside. I got the jacket, the pants, boots, and mauser airsoft, I'm building the jetpack and the helmet. </p>
<p>Excellent! Post pictures! make an instructable!</p><p>I should totally build a jetpack, that's next on my list.</p>
<p>This looks great as a display. But I dont think it will work well for a costume helmet.</p><p>I just wanted to point out for those trying to build this for a costume like I am that the pdf file for this one is not really a wearable size. Its really big! I got the whole thing assembled before the resin step and its huge! I'm making a backup from another file I found and that one can fit inside this one easily. I haven't found the .pdo version to see if that ones any better. But if you're a stickler out there for accuracy, notice the eyes on this model go to a near sharp in upper inner corners where it should be very round. Original has a bit meaner look. </p><p>That's about the source file though. Not your work. Again, you did a fantastic job! Thanks for laying out all your steps.</p>
<p>once you've built the pepakura, you can do some shaping to the eyes to make them the way you want.</p><p>As far as size, it fits me pretty well, (I must have a big head!) </p><p>Remember it's a helmet, so it should have some padding and a liner. VS an Iron man mask that is close fitting. We're talking WWII technology here, it's welded! </p><p>:)</p>
<p>It looks right on me. Now to make the backpack and leather jacket!</p>
Is there any possible way you can post a PDF file because I can't open the file on your site
<p>Trey,</p><p>I just put a .pdf on my website at <a href="http://www.monksvoice.com/Rocketeer." rel="nofollow"> www.monksvoice.com/Rocketeer.</a></p><p>I'm not sure if there will be any scaling issues but give it a go!</p>
<p>I have the PDO file for this one and more, but im not sure how to upload it. any suggestions?</p>
do you have the files on hand? may be in a pdf form? i have no program to open them up, and of course i decide to do this a week before halloween
I don't have the .pdf files unfortunately, only what I have on my server at www.monksvoice.com/Rocketeer which are the Pepakura files. I use virtual box on my Mac to run the software, and just haven't had time to R&amp;D exporting the files as a .pdf <br> <br>:(
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. <br> <br>Thank you
Sure thing!
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.
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!
Wait. Rocketeer's helmet... Cap'n America's shield... lightsaber... <br>You, sir, are officially indestructible! :) <br> <br>I love this!!! <br> <br>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.
Right now I'm working on a District 9 inspired Nerf. My Halloween costume is going to be a hot mess.
sweeet man! nice job!
Thank you! <br>
That looks amazing! Now I want to watch the movie again :)
I recently re-watched it, it's a fun movie. Seeing the GeeBee airplane featured was nice too.
Can you please elaborate more on this step I was confused reading it <br>
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. <br> <br>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. <br> <br>This is where your sculpting skills come into play, creating a smooth surface from a faceted one.
very nice job, like the welds! <br>

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Bio: I'm an actor/tech/IT/graphics/editor/writer kind of guy. I do a fair share of voice over work and have the full ... More »
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