Stormtroopers are one the most recognizable and iconic characters of all time, so with the aid of google I found this: http://paper-replika.com/index.php%3Foption%3Dcom_content%26id%3D7472:stormtrooper-helmet-with-eva-foam-pepakura%26Itemid%3D200144 the pep file is an excellent replica of the original helmet. unfortunately I only have half inch thick eva foams, but I wanted to make one, so I needed to make do of what I have.
someone asked if I could make it like a zombie apocalypse type of thing. well since I have some free time and a lot of red ink lying around might as well do some coloring. more of the details on the last step. Thanks again for viewing.
Step 1: Print and Trace the Pattern.
1. Eva foam 1/2" thick or if you got anything thinner like 2mm that would be great. The ones I got come in 12" x 12" sheets, I used up about 6 pcs of those.
2. spray paint white
3. spray paint any color (optional)
4. instant glue
5. acrylic emulsion
6. sand paper 280 or higher
7. pencil or anything that can write over the foam.
9. paint brush
10. Elmers glue
11. tons of patience (when cutting the pattern you'll need a lot of it). :)
I originally planned to glue on the pattern, but the paper did not want to stick to the foam and wrinkles started to appear as the glue started to dry. So I just traced the cutline and started cutting them up using scissors. it pays to have the pep files on the computer opened as i learned the hardway, i ended up making mistakes when joining parts up. I use instant glue as it easily welds the pieces pretty fast.
Step 2: Assemble It Part by Part
Step 3: Filling / Coating With Glue
Step 4: Paint to See Seams (optional Step)
I painted the helmet red since that's all i have available. i did this to see the seams. I sanded the helmet roughly just to smooth out the seams.
Step 5: Spray Paint White Primer and Brush on Acrylic Emulsion
Step 6: Spray Paint Flat White & Add Details
originally, i just gonna leave it plain white. but then it kinda look boring. so I was set to paint on the black details on it. I was on my way on doing that when I accidentally knocked over the bottle of black ink. I saw how the ink flowed on the helmet and liked the effect. so I poured a few more ink to complete the look.
***Updated for the bloody trooper***
When I heard of the suggestion of making the trooper bloody, my first thought was how can a trooper be bloody when all weapons are either lasers or light sabres. well, since I also wanted the trooper to stand out might as well cover it with blood.
I started by dripping more of the black ink so it would look like dried up blood. Then I mixed red ink with acrylic emulsion and painted the thing over.
Overall, I was quite happy with the outcome. it's light, wearable and could probably take a lot of play time.
The half inch eva foam proved to be better as the helmet did not require any reinforcement and held up the shape quite evenly. Only thing I would do different is to properly cut the foam and look at the pep files when doing the assembly.
It's an entertaining project for kids and not so young people. ;)