halo reach jorge helemt

So I've been commissioned me to make a Jorge helmet from halo reach.  Now I have done some research on the web especially looking at the 405th squadron that is dedicated to making halo armor.  All the credit goes to theses guys and if you are ever interested in making some halo armor check out their site.  they will walk you through the process and are a great bunch of people.  The process they use is called pepakura which is basically taking a 3d object modeling it in the computer to wire frame image and then what they call unfolding which makes you able to print it on paper and then with some cutting, folding, and gluing you get the 3d image.  then they fiberglass it and then bondo to smooth out the edges not to mention a lot of sanding and you can paint it and you have a very reasonably priced set of armor.  The thing is it takes a lot of time.  I am doing the most complicated piece of the armor the helmet. There are literally 1000's of tabs that need to be glued together.  Plus matching number to number to keep it aligned is insane.  It takes at least 1/2 hour to cut the pieces out of the card stock and then score and bend all the tabs  not to mention finding the numbers to align them and then glue them together.  If you have a lot of time on your hands this is the project for you.  It's definitely interesting and it's pretty cool to see your hard work start taking shape.  but damn is it tedious.

here are some pics of the helmet to be made and then some of the pepakura process.