Hi I'm Dan, new member, and I just thought I'd share my first build, starting with the helmet I am working on; the Destiny Warlock helmet the Skull of Dire Ahamkara which is my absolute favourite design from Destiny. I was scouring the rpf and the 405th for Pep files and found some great ones by Crimmson over on the 405th, which were already modelled and unfolded, all credit to him there. So I thought I would give it a go. (pic heavy post)
My inspiration is my own character from Destiny.

I modified the Pep file in Pepakura Designer for A4 size paper and checked the scale with the neck opening, which seemed fine for my large-ish head (about 61cms around)
I printed onto 250gsm/ 100lb cardstock which I got from 2 Daler Rowney Bristol Board pads
Building
I started with superglue but quickly moved onto a hot glue gun as this sped up the process considerably

My first go at Pepakura. I know Pep takes a long time but this seemed to take forever, as parts overlay and fold back on each other.
The finished Pep helmet
Next was the fibreglass resin on the outside. For this I used David's Fastglas Resin which I got from Halfords (UK)

Applied Resin

I decided to go with a casting plastic to harden inside, mainly because the mandible and horn parts meant that fibreglassing the inside would be next to impossible, short of cutting them off which I was not keen on. I used Polycraft Polytek Easyflo 120 which is a 1:1 polyurethane plastic, which I got from here: http://www.mbfg.co.uk/polyurethane-casting-resin/easyflo_120.html
The nice thing about this is that it is sold in numerous quantities. I got the 2 litre kit which contains a litre of each, part A and part B. I slushed this inside, trying my best to cover all the inside evenly, including the mandible bits which I could not see down into.

It ended up coating quite thick in some areas, especially in the horns and I had a few wayward drips which I can just cut and sand. This has left the helmet fairly heavy and I would definitely try and go for thinner coverage next time.
I am now at the bodyfiller (Bondo but not bondo) stage, for which I am using a filler called P38 (also from Halfords)
Thanks and I will update as and when there is something to update
Any feedback, tips, tricks and comments most welcome.
My inspiration is my own character from Destiny.


I modified the Pep file in Pepakura Designer for A4 size paper and checked the scale with the neck opening, which seemed fine for my large-ish head (about 61cms around)


I printed onto 250gsm/ 100lb cardstock which I got from 2 Daler Rowney Bristol Board pads
Building
I started with superglue but quickly moved onto a hot glue gun as this sped up the process considerably




My first go at Pepakura. I know Pep takes a long time but this seemed to take forever, as parts overlay and fold back on each other.


Next was the fibreglass resin on the outside. For this I used David's Fastglas Resin which I got from Halfords (UK)

Applied Resin




I decided to go with a casting plastic to harden inside, mainly because the mandible and horn parts meant that fibreglassing the inside would be next to impossible, short of cutting them off which I was not keen on. I used Polycraft Polytek Easyflo 120 which is a 1:1 polyurethane plastic, which I got from here: http://www.mbfg.co.uk/polyurethane-casting-resin/easyflo_120.html
The nice thing about this is that it is sold in numerous quantities. I got the 2 litre kit which contains a litre of each, part A and part B. I slushed this inside, trying my best to cover all the inside evenly, including the mandible bits which I could not see down into.



It ended up coating quite thick in some areas, especially in the horns and I had a few wayward drips which I can just cut and sand. This has left the helmet fairly heavy and I would definitely try and go for thinner coverage next time.
I am now at the bodyfiller (Bondo but not bondo) stage, for which I am using a filler called P38 (also from Halfords)
Thanks and I will update as and when there is something to update