Re: Robocop: The Original for Pepakura **UPDATE-> HELMET FOAM TEMPLATES POSTED**
Hey guys, love the work you are all doing here. I was thinking about trying a Robocop helmet myself. As WarPig mentioned foam can be heated and molded. Here is how I do it, I hope it can be of some use to someone.
Here is what you will need.
An oven.
The piece of foam you need molded.
Two childrens plastic hard hats.
Some tape.
Scissors.
You may also find having a second pair of hands to be helpfull.
The first step is probably the most inportant step of all, and I can not put enough emphasis on this step!. MAKE SURE YOUR WIFE IS OUT OF THE HOUSE, as you will need to use the oven.
Once you know she is out of the house and will not be back for around 20 minutes or more, you can begin.
Pre-heat the oven to around 200F, ( the actualy temperature of the oven will depend from oven to oven). Place the foam inside the oven for 10 seconds ( you may have to play around with the length of time until you find what works for you) You don't want the foam to melt of burn. You just need it soft.
You want to be quick with this part as the foam will start cooling straight away. Take the foam out of the oven and lay it on top of one of the plastic helmets, then quickly place the second helmet on top of the foam and push down, sandwiching the foam in the middle.
This is where a second pair of hands can come in handy. You need to tape the helmets together keeping them pressed together as tightly as possible. It can be done by yourself, but I dropped the tape and needed the help of my youngest boy to pick the tape up for me.
Now you need to let the foam cool down, luckily for me it was winter when i did this one so I was able to stick it outside for 5 minutes. On a warm day you will want to leave it for a while.
Once the foam has cooled down it is time to cut the tape and remove the plastic helmets.
OK, so here we go, lets see what this baby looks like. Not bad for 5 minutes work. A nice looking dome.
I used this method for making the top of my Batman cowl and Ironman Helmet.
Hope this can be of some help.
Familyman..