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I made a Master Chief Helmet from Halo a couple of years back for a space girl shoot. I didn't really finish it to a high standard, just painted it up with all the facets still in place. Seemed to look OK to me, however I liked the Pepakura system so I decided to look around for a Predator Bio helmet design and I found this PEP file
Here
You will need the Pepakura Designer software which can be used for free with limitations. You can get the software
Here
I downloaded the PDO PEP files, then had to re-arrange it because I am using A4 card for mine and the PEP is set up for Letter. No big deal, just shuffle the bits around.
I did find a different PEP file set up for A4 AFTER I had finished this, so I may decide to build that as well later.
Here
You will need the Pepakura Designer software which can be used for free with limitations. You can get the software
Here
I downloaded the PDO PEP files, then had to re-arrange it because I am using A4 card for mine and the PEP is set up for Letter. No big deal, just shuffle the bits around.
I did find a different PEP file set up for A4 AFTER I had finished this, so I may decide to build that as well later.
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Signing UpStep 1Print, cut out and assemble
After you have downloaded the PEP file, use Pepakura to print it out onto card stock. I use standard card for this, it available at any good stationers or office supplies retailer. It's basically greeting card thickness, quoted in Europe as 180gsm, I don't know the US equivalent.
I used yellow card since that's what I had in stock.
This PEP came out at 8 pages. I began with the crown and worked my way downwards carefully cutting out the sections and gluing them together with general purpose glue.
Very fiddly, and time consuming. It took me two evenings of solid work to produce the card model. Some bits didn't seem to have quite the right contours compared to the movie stills I was using as a reference. The jowls seemed too flared out. I eventually put a strip of masking tape across the back to pull the mask into a better shape.
I used yellow card since that's what I had in stock.
This PEP came out at 8 pages. I began with the crown and worked my way downwards carefully cutting out the sections and gluing them together with general purpose glue.
Very fiddly, and time consuming. It took me two evenings of solid work to produce the card model. Some bits didn't seem to have quite the right contours compared to the movie stills I was using as a reference. The jowls seemed too flared out. I eventually put a strip of masking tape across the back to pull the mask into a better shape.
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I very much doubt the legality (or safety) of actually trying to make an entire helmet for use on the roads without some sort of safety certification. You don't say what country you reside in but if it's within the EU then this would almost certainly be illegal.
It may be possible to make the mask as part of the helmet visor, but again I think the limited visibility would be a cause for concern.
On my Biomask i have added LEDs as well but i have put them in with a switch to kill the circuit but also a reed switch as well and a magnet in the latex mask so when i put the mask on the LEDs turn on and when i remove the biomask they turn off automatically.
I'm considering making the shoulder weapon though .....
the shoulder weapon i have given some thought to, i'm thinking i will put a servo in it so i can make it retract to the safe position.
From what i can tell you use your stuff for photography so that wouldn't be required.
You could make the weapon from foam board by layering it up, and you can cut it using a polystyrene cutter or sharp knife, you could even make it out of polystrene