Just to reiterate what SpArtan-270 said, scratch-building is a very good option if you don't have the money or experience to create a pepakura helmet. Sadly, because scratch building is exactly that, building from scratch, there is no easy way to make a tutorial for it. I've scratch built many different things out of cardboard and know just how rewarding it can be. All it takes is a good eye for detail, a little patience, and, of course, some cardboard.
From my own experience I recommend using different thicknesses of cardboard for different parts of the helmet; from thin cardboard off of a twelve pack of soda to get really detailed folds and such, all the way up to corrugated cardboard for more rigid sections, it's all about using the right cardboard for the right job. I also would recommend using hot glue or even wood glue because of how strong they are. The only downside to wood glue is how long it takes to harden.
ERADICATORofDTH said:
Ok so what you are saying is print out the sheets, cut them out, glue them to cardboard, cut out the cardboard, and sorta fold how you would normally do with paper, just with cardboard? Also, is the helmet a one size fits all? Is it possible that it could be too small?
It's quite possible that it might come out too small or too large, but if you follow the scaling tutorial in the pepakura section of the boards, you should be able to get the sizing just about right your first time.
That's one of the advantages of scratch building...you know it fits, because you made it to fit.
Good luck with your project, if you do decide to build a helmet out of cardboard I hope you post your progress, it's always nice to see how a project develops, especially when someone decides to use a less conventional method.
^-^Foxy~>