Project stats thus far Start date: Sat, Jan 8 Foam: 1 sheet (2'x2') Formed: Helm, L. forearm All pictures: http://s1087.photobucket.com/albums/j479/Puppyloveconnex/ First step was to print the patterns (without tabs) cut them out and join some of them prior to cutting the foam. Cutting out the shapes took about 3 hours, I used a ruler and razor and some wood carving tools. I also scored the back with a wood burning tool, lightly for rounded and deeper for sharper corners (mountain folds only) and cut about 1/2 through the foam for valley folds. Also, I used sharp scissors to cut angles on any pieces that connect with others on a mountain seam. Then I started to assemble, doing the large pieces first It formed quite nicely, and you can score the inside to further form it as you go. I did have to do some custom work around the front, and it still needs alot of work... but overall I am happy with the results. OK, onto the torso, larger, but should be easier as there are less tiny pieces.