Introduction: How to Make a Cosplay Helmet!

About: Just a little guy from Brazil wanting to be happy and make things!
Always wanted to make a helmet from Halo, Daft Punk, Gears of Wars, or any other iconic character that you like a lot? This instructable is for you! (And it works for armor too!) 

Obs: This is my first instructable, and if there is any grammar mistake, sorry, english isn't my first language! and the .PDO for Guy's Helmet is in step 2.
Obs²: Gloves tutorial are now on page 10!

Step 1: Materials

FIRST: If you don't have patience, just leave, you need A LOT OF PATIENCE!
*Pepakura Viewer 3
*.PDO file of your desired helmet (.PDO for Guy's Helmet is in step 2)
*Paper (Of any kind, but I use cardstock)
*Scissor or X-acto knife
*Fiberglass and Fiberglass resin
*Bondo (Car Body Filler)

Step 2: Paper Model!

Print out your paper template in Pepakura Viewer, cut out and start gluing everything in place! (How to do this is theme for another instructable)

Here's a tip for gluing the parts togheter:

Update: I've uploaded the pepakura files for people that wants to make the same helmet!

Step 3: Fiberglass!

Apply your fiberglass mat or cloth and resin over your paper helmet or armor, let it dry and it will be hard as a rock!
(TIP: Fiberglass the inside, not the outside as I did)

Step 4: Bondo!

Apply bondo to the places you need to get smooth! (Normally round or curved places, straight parts don't need to be "bondo'ed")

Step 5: Sanding! (And Lots of It)

Take your various grit sandpaper, and start sanding from 150 grit, until 600 or even 700 grit! Get everything nice and smooth or you may regret it in the future!

Step 6: Painting!

Take your spray paint and put a layer of primer on this helmet! Sand off any imprefection and primer again if needed! Then, your final color and a layer of clear laquer!

Step 7: Visor!

Next you need to add a vior, and you can buy plastic, plexiglass, a motorcycle helmet visor, but in my case I needed to vaccumform a visor! And attach it with superglue or hot melt glue!

Step 8: Last Details! (Optional) (LEDS)

Depending of the helmet you're making, you can weather the painting, or in my case, I added the LED lights in the helmet!              

Here's a video of the LEDs:

For those interested in the electronics things, I simply used a 555 timer and a 4017 decade counter to drive 16 leds boards with 4 leds each, and two more differents boards, with 8 leds each, and two other boards that are not connected to the 555 circuit, but still, have 4 leds each, with ~90 leds in total! Everythings runs out of 8 AA batteries (12v)

Step 9: Be Happy!

You have now completed a helmet or armor for a cosplay! Goodbye and be happy! See ya' in another instructable xD

Step 10: Quick Uptade! GLOVES!

So, I've found the photos I took when making the gloves, so why not show how I made it for you guys?

Step 11: Make a "Blueprint"

Draw your hand in a piece of paper, just like you did when you were a kid, and draw the little pieces on each finger! You just need to make one side, because both sides are the same, but the big hand piece, this one, you need to make one normal, and one mirrored for the other side! Remeber to leave your pieces between two finger joints, or else, you won't be able to flex your hand!

Step 12: Cut'em All!

Take some type of hard plastic, that is slightly curved, and use your patterns you made before and cut them, every piece will have a duplicate! And sand the sides smooth with some fine grit sand paper!

Step 13: Painting!

Primer all of them and use the same paint you used to paint your helmet, so the colors will match! There is no need to sand between paint coats, but some hard work will be worth on the end! Again, remember, PRIMER, COLORED PAINT, ENAMEL!

Step 14: Glue Them!

Find some nice gloves, all black if you can, and use some hot melt glue to glue them in place! Wear the gloves, and ask someone to help you glue the pieces in the gloves! You don't need too much glue, just a little drop is sufficient!

Now you have your beautifull pair of gloves! Now go be a Daft Punk!

LED Contest with Elemental LED

Runner Up in the
LED Contest with Elemental LED

Halloween Props  Contest

Participated in the
Halloween Props Contest