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Using Paper, Resin, and Fiberglass to be the Master Chief!

Step 3Setting up and printing

Setting up and printing
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  • C:\1stuff\pictures\MJOLNIR\Pepakura Designer.JPG
  • C:\1stuff\pictures\MJOLNIR\PD2 paper size.JPG
Ok, now that you've installed Pepakura Designer and downloaded your .pdo files, it's time to open Pepakura Designer. So open it up, go to file, and click Open. Point the file browser to the folder you stashed those .PDO files in. For this step I'll be using the Right-Bicep file. Open up Right-Bicep.pdo and you will see two sub-windows. On the left, you have a 3D model of what you will be making. On the right you'll notice a grid with odd-looking pieces in each cell. What you see is the magic of Pepakura Designer 2. It takes 3D models, and through user-manipulation, creates 2D pieces that can be printed on paper, then cut apart, folded, and glued together to create 3D pieces. I'll get to that in the next step so for now let's focus on getting this to paper.

Once you've opened the .pdo file, you'll want to click on the "BothWindows" tab and uncheck "use materials for faces". this will make the printed pieces while as opposed to gray, saving you ink. Don't mention it.

Now you'll need to specify your paper size. if you're using A4 size paper, then skip to the next step. Otherwise, listen up. Click on "Configuration" in the toolbar, then click on "Print and Paper Configuration". In this example, I will be using Letter size(8.5x11 inches) paper. Select "Letter" from the Size drop-down menu, and adjust both margins to 5 mm. Hit OK and notice that those pieces on the right side of the screen are now jumbled up out of their page boundaries. While you might be compelled to re-arrange them, it is not that time yet.

To make the completed Pepakura piece scaled to fit your body type, you'll need to do a little math. I learned the following formula from the 405th.com forums. Measure your height in inches (I'm 6 foot even, so that's 72 inches). Then add 3 inches to that measurement.(for me, 75 inches). Divide that by 86(75/86=0.872093). Then multiply that number by the scale of the current piece you are working on (Right Bicep's scale is 30.342, so 30.342x0.872093=26.461045). Take that last number(26.461045), go to 2DPatternWindow, then click "scale up/down development by specifying value...". Highlight that current scale and replace it with the one you just calculated.

Now all the pieces have moved again. Aren't you glad you held back from moving pieces the first time? So to finish up, you'll need to get all the pieces into their page squares. To aid this, click "Configuration" and click "Show Only 2DPatternWindow". Now you have a larger screen area to move these pieces in. By scrolling the scroll wheel, you can zoom in and out. Right clicking and dragging the mouse moves the camera view, and left clicking on a piece and dragging moves the piece.

Now, pretend you're 6 years old again. Remember those lines between the sidewalk? You know, the ones that you couldn't touch for some unspecified -yet given- reason? It's the same deal here. You don't want the individual pieces touching the grid lines. So get all the pieces off those lines, and keep them from touching each other. If they do touch the lines, they will be cut into pieces between sheets, meaning you'll have to rejoin em later. It's up to you how many sheets of paper you want these pieces to print out on. If you want one piece per sheet, that's fine, but it takes up extra paper. If you can manage to get two on a sheet, saving one sheet, Greenpeace will love you.

So once you have all your pieces arranged, it's time for one last detail. Click "File", got to "Printer Setup" and change orientation to landscape. Just to make sure you've got this right, check "Print Preview" out. as long as all the pieces look whole, you've done good. Time to print! (If PD2 says "A part of development may not fit into printable area" and asks to scale, click "No")
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30 comments
Nov 21, 2007. 5:18 PMjgderuvo says:
Jake, great instructable. However, I'm a tad fuzzy on the scale issue. Where did you get the scale of each part? Sure wish you used the helmet as an example instead of the bicep! Thanks.
Mar 12, 2012. 4:09 PMHumbleSwordfish says:
Hey Jake, I'm sort of clueless with this pepakura viewer mumbo-jumbo, and I don't even know if you'll answer this :b But where exactly do I find the "Scale development up/down by specifying number"? I can't seem to find it anywhere... I'm using the version 3.0.4 or something (the latest as of my posting date). Thanks mate!
Sep 26, 2009. 10:14 PMQidlo says:
Hey EVERYONE. You don't need to arrange the parts on the pages by hand, click the "recalculate parts layout" button (looks like 4 sheets of paper arranged together) , then click "Manual, then make sure the "Scale" is set to your height in inches. Also, the whole calculation thing is unnecessary if you are using the PDO by ROBOGENESIS. Just replace the 86.00000 with your height in inches.
Aug 5, 2009. 9:32 PMGamerGear says:
I have a question how do you print individual pieces using pepakura? say you messed up a piece and need to reprint just that one piece or say you printed all of the pages except the last page of pepakura files because your printer ran out of ink? lol
Nov 9, 2007. 5:12 AMflamerz14 says:
How do you measure this part for MC's helmet?
Nov 9, 2007. 5:38 AMflamerz14 says:
Is it me or did the size of the helmet just shrink from the original? Original: 39.1 x 27.8 x 40.7 my calculations(i'm about 68inches): 26.7 x 23.2 x 34.0
Jan 23, 2008. 12:08 PMrandomman says:
Mine got bigger... In fact, I did the math (I converted from cm to inches and then inches to feet) and it says it will be 4 feet tall. Obviously, this is not how it should be... my height is 6 foot 3 1/2 inches. Would your scale work for me you suppose? Because then I'll just copy/paste that one in there... otherwise, I should find out what I did wrong in my maths...
Aug 3, 2009. 7:57 AMRC-0720 says:
don't convert it. just treat it like inches, and go from there.
Jan 23, 2008. 1:46 PMrandomman says:
I think I'll just try using your scale. Also, how much resin/fiberglass would I need for just the helm? How much would that cost? And how detailed can I get? I was watching a machinima and it looks like the actual helm has some kind of ventilation slits in the top... I don't know. But yeah, I'm goint to use the one you put in, as you said it would work for people seven fot tall, and i'm about 9 inches shorter than that...
Jan 24, 2008. 6:59 PMrandomman says:
Thank you for giving me that calculation, but I now know one of my mistakes: I'm 63 inches, not 6 foot 3 :downs: anyways. Rather than downloading a new helmet model and reprinting it (I already did it with the one you have posted in there with the scale) and using up another possible 14 pages, do you suppose I could build the pepakura and then add changes in the paper myself? It's not so much the curves I'm concerned about... If you compare a picture of master chief's head to the helmet in the pepakura there are a few considerable differences, these including (but not limited to): the vents along the top of the helmet, the front of the helmet (just below the visor) and maybe more. Do you think I could modify the paper model (after putting it together) and the resin it to look that way? And will it really affect it that much to have the helmet on the scale provided in the instructions rather than my own? I mean, I would have room to grow... But yeah, thanks for your help on all this.
Dec 23, 2008. 8:18 PMDivinus says:
Where did the 86 come from? I understand how it works, but the 86 bugs me because I don't know where it came from. Thanks!
Aug 3, 2009. 7:55 AMRC-0720 says:
the 86 is the height that MC is. it was what they scaled the armor as. technically, his full height, minus armor, would be 84, but the 2 extra inches are the bulk of the armor adding up.
Nov 12, 2008. 4:40 PMoaky8 says:
OK so I printed out the helmet and glued it up, but it does not fit!!! like my head wont fit threw to opening. i scaled it to 23.4621. i am 5" 5.5', i also added only an inch for extra room. what did i do wrong? i can't register for the 405th forum so i have to ask here.. very nice Instructable by the way. I had found all of this into on the 450th, that took a lot longer than reading this.
Aug 3, 2009. 7:54 AMRC-0720 says:
okay mate, the solution is pretty easy: you misscaled it.
for scaling, you take your average height, which, for you, I would say would be 66", plus at least 2 inches, to give room for the bulk of the armor, which would result to 68". next, divide your number, 68, by 86. take the result, and multiply it by the number that the automatic scaling thing gives you. replace that number with the new number, then shift your armor pieces around, then print. if it still doesn't work, I would suggest that you go for the armor pieces by Robogenesis on this site:
http://halocostuming.wikia.com/wiki/Pepakura_File_Index

it should give you better stuff, with slightly more details. good luck.
Feb 14, 2009. 7:52 AMcrazyscott85 says:
Same thing here. After I fiberglass it Ima cut an opening bigger so my head fits
Jul 6, 2009. 11:02 AMthe118sparten says:
how do you glue the paper together?
Aug 3, 2009. 7:49 AMRC-0720 says:
I would suggest that you try Elmer's glue. it works.
Apr 3, 2009. 4:18 AMJust BLUETOOTH says:
NICE
Feb 20, 2009. 10:19 AMcurtreid8 says:
hi this instrucable is pro, hovever i have a problem, ive made my helm, but when i try and make the chest piece the numbers dont match up what i mean is 100 on one side is big and 100 on another piece is really small so it doesnt match up ? ? ? im reaalyy confused
Feb 27, 2008. 11:44 AMHalotriple3 says:
hey jake, so i made the chest and the crotch, but they're way to small,and dont fit together. I followed all of the instructions. i even cut some parts of it so it would fit. i dont get it. my friend is also making one, and his fits perfectly. what did i do wrong?
Feb 27, 2008. 1:05 PMHalotriple3 says:
well, does ajusting the scale to the printer shrink it? cause i did that on accident.
Feb 27, 2008. 6:22 PMHalotriple3 says:
nooooooooooooooooooooooooooooooooo!!!!! wow that took like 5 hours. dang!!!
Feb 25, 2008. 7:04 PMphinns1988 says:
what if I'm on my laptop and I dont have a printer saved to it. I tried saving to my flashdrive but it wont work
Feb 3, 2008. 4:22 PMEleMeNt778 says:
Thank you so so much!!!
Feb 2, 2008. 8:56 PMEleMeNt778 says:
hey, I tried to print it out right now and it cut off pretty much everything. Why did it do that? None of the pieces were touching the grid lines. Help me out Please!!!

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Author:Jake Turner(Jake Turner)
Where to start... I get bored and reach for either a soldering iron or a keyboard. I have a short attention span. I love working with electronics, eating pizza, and making all sorts of things. I've be...
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