Tutorial: Every Step from the beginning to the end!

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FirePhoenix

Jr Member
Ok, before we start I would like to say that I just combined all tuts and added my own experience/thoughts to it.

IF ANY MAKER HAS OBJECTIONS I WILL PUT IT OFF..

MORE PICS ON THE WAY!!!!!!

Here we go:

Step 1: Downloading

Download the file you want (normally it's the Halo 2 helmet) and open it in Pepakura Designer:

Link to the Halo 2 helmet:
(Thanks to Jedifraz for the hard work of making it)
Helmet

Step 2: Scaling

Scale it by using this formula:

Credits: FrizzleFry

Get your height in inches (you may want to add like 2/3inches more for more space)
Divide it by 86
Multiply the result by 30.342

I.E:
71 / 86 = 0.82558
0.82558 x 30.342 = 25.04979

In pepakura go to 2dPatternWindow tab and select "scale Up/Down by specifying value" and enter the result in the Scale box:
(In this case it's 25.04979)

Step 3: Pepakura settings and printing

Note: This is for A4 format users.

Get your Cardstock and put it in your printer.
Go to the BothWindows tab, and uncheck "Use Materials for Faces".
Go to your printer settings (not the ones in Pepakura Designer!) and make it print "Landscape"
Print!:D

Step 4: folding

Credits: Iceman29

things you will need:

Ruler
2 pens with diffirent colors
Scissor
Low temp glue-gun with patrons

Alright, first off you take the Ruler and the pens:

Assign the pens to a certain fold (you can look up which fold is the valley and which is the mountain at the configuration tab and selecting "line style configuration")

I.E:
blue pen = Mountain fold lines
Black pen = Valley fold lines

Now put the ruler at the lines and use the pen to make a clear and straight line on it.
It will look like this:

(Note: Not my pic)
DSC01303.jpg


Next thing to do is cutting out all of the parts and folding it correctly.
When everything is folded you glue the matching parts together

You should now have a Helmet made out of cardstock
It should look something like this
daaa.jpg


Step 5: Resining

So you've made it this far?
Well, now it's time for the big work.
First off, you will need:

Latex gloves
Respirator
Protective eyeglasses
Resin (Duh)
Hardener
Brush
Can

Alright, what you need to do now, is this:

Make sure that your helmet is free of dust/debris/other things.
Mix the hardener and the resin in the can. (Make sure to use small portions)(for mixing, please look at the instructions at the back of the resin can)
Paint a thin even coat over the cardstock and make sure you have the paper soaked + a layer of resin on it.
Let it dry for a while.
You may now cut out the visor/vents.

This is what it may look like when it's done.
DSC02078.jpg

Note: This is another helmet

Step 6: Fibreglassing the inside

You'll need:

Latex gloves
Respirator
Protective eyeglasses
Resin
Fibreglass
Hardener
Brush
Can

Ok, before we start, cut out some strokes of Fibreglass.
MVC-474F.jpg

Once you're done with that lay them inside the helmet and make sure everything is covered with fibreglass.
(If you want, you can glue the fibreglass to stick them on to the helmet already)

Mix the hardener and the resin. (use bigger portions this time)(for mixing, please look at the instructions at the back of the Resin can)
Now paint the fibreglass with resin, make sure it's soaked and there ain't bubbles.
After about 20/30minutes it will become very hot and very hard, this is good.
Let it dry/cool down.

Step 7: Bondo-ing

You'll need:

Latex gloves
Hardener
Bondo (or any good substitute)
Putty Knife

let's get started, you might want to sand it first
Mix the hardener and the Bondo. (make sure to use small portions)
Scrape it on your putty knife and start smoothing the helmet
Once you're done, let it dry.

Afbeelding001.jpg

Note: this is another helmet.

Step 8: Sanding

You'll need:

Sanding paper or a black and decker mouse sander

Basically what you do is:

Sand it so its all smooth.
Make some parts more angualar.

Step 9: adding details

Credits: DarthCalibar.

You'll need:

Some sort of plastic or cardboard
Scissor

In this case we'll use the brim as example:

Draw the brim shape onto paper, then draw the detail stencil inside the brim outline
Cut the brim detail out of a piece of material with some thickness... a plastic "For Sale" sign, foam board, card board... whatever like you can find
Glue this to the underside and fill in the edges with a bit of putty, glaze, hot glue... just remember it has to be paintable

Here's a image explaining it:
da.jpg


Step 10: Primer and Paint

We all know how to do this soo...

You can now insert your visor.

I would like to thank everyone on this forums for Helping eachother out :)

cya,

FirePhoenix NL
 

FirePhoenix

Jr Member
Step 11: Leds
Credits: Link4044

Ok, so you want some lights? here's how to make some.

Firstly, you'll need:

Soilder Iron
Soilder
Flux Paste
Red Wire (20gau)
Black Wire (20 gau)
Resistors (100 ohm)
Leds
Switch
9V
9V connector
Wire cutter

This is what it looks like


Here we go:

A led has a long (+) leg and a short (-) leg
What you now need to do is, bend a short leg out on one LED then on the other bend the long leg.. this is called series
Now add Flux to one of the legs
Soilder the legs together.
Once you're done with that you have to soilder a resistor to the unused Long leg

It should now look like this


Next soilder the red wire to the resistor then the switch
Then soilder the connector to the red wire
Now soilder the black wire to the short leg on the other LED

It should now look like this


Now the only thing left to do is to add the 9V
You can now add it into your helmet or get more leds and then embed it

Step 12: Fans
Credits: Sikarian (Thanks for correcting me)

Things you'll need:

Red Wire
Soldier
Soldier Iron
Flux paste
12V Fan
Switch
9V
9V connector

Okey,

The 9v connector normally comes with a black and a red wire attached to it.
The 12v fan normally comes with a black, red and a yellow wire attached to a plug.

What you need to do is this:

Solder the black wire (from the connector) in to the plug.
Solder the red wire on the switch and solder another red wire onto it.
Take the last wire and solder it inside the plug.
Ignore the yellow one.

Here's a picture explaining it
fan2.jpg


You can now place it into your helmet.

Step 13: Vents
Credits: MandoMan531

You'll need:

Wire loom
Knife

This is wire loom


What you need to do is this:

Cut out the space between the ridges of the loom
Make sure it's still connected to eachother

It should look abit like this
vent2.jpg


DOUBLE VISOR TUT INCOMING :)
 

Macattack64

Well-Known Member
AoBfrost said:
Good tutorials.
Did you ask for permision to use them? Some of them were from other members.
Yea that's what I was thinking... You better/should have asked them... If you haven't already...
 
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FirePhoenix NL said:
Step 9: adding details

Note: This is Spase's little Tut. (I shamelessly copied it)

You'll need:

Some sort of plastic or cardboard
Scissor

In this case we'll use the brim as example:

Draw the brim shape onto paper, then draw the detail stencil inside the brim outline
Cut the brim detail out of a piece of material with some thickness... a plastic "For Sale" sign, foam board, card board... whatever like you can find
Glue this to the underside and fill in the edges with a bit of putty, glaze, hot glue... just remember it has to be paintable

Here's a image explaining it:
da.jpg
Edit:
Nevermind, The credit for the tutorial you used goes to spase. I thought you made it based off mine. I didnt think spase used any plastic.

Carry on.
 
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Walter Spase

Well-Known Member
Lol... actually I did use the same technique in a few places, parallel to you, and I posted that picture trying to explain to Firefox what both of us did... he had me confused for you at one point... and I actually gave credit to you when I posted it... lol... oh well

Edit: And I did use mostly glaze and a Dremel to get my details..

Link with credit given where credit is due
 
Spase said:
Lol... actually I did use the same technique in a few places, parallel to you, and I posted that picture trying to explain to Firefox what both of us did... he had me confused for you at one point... and I actually gave credit to you when I posted it... lol... oh well

Great minds think alike. :D
 
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AoBfrost

Well-Known Member
Cardstock and the for sale signs have a similar thickness, for the helmet peice, you could use cardstock to make that pattern.
 

FirePhoenix

Jr Member
Heh, sorry all.. i just thought it would be handy when all tuts would become one =P

anyways.. if anyone has any objection.. i will take it out.

and sorry spase/darthcalibar i will fix it.

Edit: ok i've given (i think) every maker credit now. correct me if im wrong.
 
FirePhoenix NL said:
I know I may not double post but hey, the Led part is up..

Thanks to Link4044 with his great tutorial :)
I need the fan/vents right now. Can't wait till u post it!!!!!!!!!!
 
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Good tut but not detailed enough, as you just combined other peoples. Ill be comin out wit a complete step by step detailed one soon. I'd do video but idk how to put vids on a computer and edit. You should add more info that is your own to make it more detailed, that is if you have any.
 
Master Chef said:
Good tut but not detailed enough, as you just combined other peoples. Ill be comin out wit a complete step by step detailed one soon. I'd do video but idk how to put vids on a computer and edit. You should add more info that is your own to make it more detailed, that is if you have any.
Well if you have Windows Movie Maker that's what i use. And usually al you have to do is take the memory card out of your camcorder and put it in the comp. Then click save files bla bla bla. Then go to WMM and open the file and wala!
 
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