This is how to make cheap props for costumes and stuff by recycling materials you already have.

This helmet was made from cardboard following an instructable by Honus.

Step 1: Materials

You will need:

Cardboard ~ not the corrugated stuff unless you want it to look crappy I used the backs of some desktop calendars...the big ones 42 x 64

Glue ~ Any kind will work as long as you seal it before resining or painting. I use white glue and hot glue The white glue is for smaller details, and the hot glue is for big stuff or stuff u don't want to hold for a long time while the glue sets.

Clamps ~ Small clamps for holding glued pieces together Bulldog clips or clothespins will work too.

Sculpting medium ~ I used wallboard joint compound because thats what i had on hand. You can have better results if you use bondo or some other medium.

Pattern ~ Don't just throw something together. Make a plan! There is a paper modeling program called Pepakura that is very useful if you want to make a prop from a 3d file. Click here to get it

Sharp Knife ~ Xacto knife or something similar with brand new blades (blades will get worn out quickly cutting cardboard)

Sandpaper ~ For sanding...duh

Paint ~ O.o

Greeblies ~ Random junk to give it character
hey great job, could somebody help me with making this >
first we need a 3d file of the helmet then we can use pepakura to make it real
I just read a <a rel="nofollow" href="http://405th.com/forums/index.php?s=c5140373f9110838f19afb5e372f8a51&showtopic=8505&st=0&p=118535&#entry118535">forum</a>forum with this problem and they said the helmet was too complex to build <br/>
Nothing is too complex to build!<br /> Some just take more time then others.&nbsp; :P<br />
well you could still make it, you just cant use pepakura or a 3d file. Just eyeball it
That one is a bit more complicated. It has lots of subtle and complex curves. It can be done, but there is a lot of work to be done during the smoothing process. I have started a stormtrooper helmet, and it is extremely tedious around the aerators.
mr.dr.prof.joel<br/>check this page:<br/><a rel="nofollow" href="http://www.tamasoft.co.jp/pepakura-en/gallery/ranking.php?len=20&amp;sort=0&amp;cate=-1&amp;lim=20&amp;search_words=#NO">http://www.tamasoft.co.jp/pepakura-en/gallery/ranking.php?len=20&amp;sort=0&amp;cate=-1&amp;lim=20&amp;search_words=#NO</a><br/>13th model down.<br/>
<a rel="nofollow" href="http://www.youtube.com/watch?v=9MfQKxccyr8">http://www.youtube.com/watch?v=9MfQKxccyr8</a><br/>YouTube - Dave's R2 Demo<br/><br/>my prop of r2. cdrom sound, 2 12 v gell cell batteries, a/c inverter, hitech radio, saturn windshield motors for feet, 2 boat speed controllers. dome turns too. <br/>
That's awesome man, I can't wait to see it wen it's done. Did u make the dome, or have one made? I have one in the works, but it just looks like a trashcan with electronics stuffed inside atm. I haven't spent any cash on it yet (just using what I got). I am thinking of vac-forming the dome--I think it will be much cheaper than having someone cast or mold one out of metal.
aspects superdome. a squirrel cover for birdfeeders. or an 18" security cam cover
Awesome Master Chief helmet, I have the real legendary edition one. You should post an Instructable on making that.
Did you want one on modding the Legendary helmet to be wearable, or did you want an instructable on the scratchbuilt one?
Both would be <em>awesome</em>!<br/><br/>Probably the wearable Legendary helmet first-- I look forward to doing that sometime soon with good directions.<br/>
I don't have one, so i will have to do it in photoshop or something, but i have done it for other ppl, so i know what to do :P Build a vacuform table in the meantime, just google it there are lots of cheap designs and all u need is a vaccuum cleaner with a hose. There will be more details in the instructable coming soon :D
Not advertising or anything but if you want to know how to make the pepakura helmet(mc)here is the forum with all the information<br/><a rel="nofollow" href="http://www.405th.com/">http://www.405th.com/</a><br/>

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