This is my very first attempt at halo armor using this method, so bear with me and I an VERY open to suggestions.
The material I plan to use is 3mm sintra (pvc foam board). This helmet is not for me, but is a late Christmas gift for my best friend, as well as a test bed for possible armor production (for sale). It will include the build, the painting, and the installation of electronics. However, first this is first.
I am using the file MJOLNIR Mk.VI [HD] (JTM HD mk vi).pdo from the database, made by JTM1997.
The first thing I had to do was modify the file slightly for the medium. Since most of the pepakura is made using thin (like ¼ mm) cardstock, I needed to do away with some of the details that the pepakura would show. However, that is not a bad thing in this respect. Most of the edge detail is unnecessary because the 3mm sintra has its own edge that is… 3mm.
With that in mind, I went through and trimmed most of the pieces after modifying the scale. Her head is 8.5”, so I upped it to 10” for padding and scaled it appropriately.
As you can see, some of the pieces still have a bit on an edge to them. That is for depth. Most of those pieces are level on one side and sunk on the other. I realize that what I am taking about will cause a few holes in the build. Well, I have a cure for this… bondo.
However, not all the holes will be covered and plugged. On the top, the overlapping flaps will include vent holes and the cheeks (under the hoses) will likewise be open. Both areas will receive fans during the electronics phase for pumping out the air and sucking in the air to defog, respectively.
I will be printing this out today and will update shortly after.