You can test the pieces' fit after completing them, but be careful not to damage them. The best models I've used have been by "ForgedReclaimer", "Rundown" and "元X BLU3R1V3R". Something that looks game-accurate may not necessarily be the best one to use due to anthropometrice of the human body. Aditionally, you'll get a feel for what makes a good model as you work. Identifying these parts and not scoring them will save you from smoothing them out with isopon later on. All tabs on pepakura models have fold lines at the edge, but there are some cases where it should actually be a smooth bend. Superglue was the best method of gluing the pieces together, although only the more viscous brands seemed to work. As long as the lines you score don't deviate from the printed line (About 0.3mm), you should be able to avoid warping. There's always some tolerance to error when cutting the pieces, but the most important part is the fold lines. For beginners, the edge ID feature in pepakura viewer is very useful for telling which parts fit together.
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UPDATE: Scaling spreadsheet made - Check download links on previous pageġ60gsm card is a good compromise between ease of cutting, and strength. If there's enough interest, I might make a chart (Or spreadsheet that you can enter your height in) to show the required scaling factor for each part. Just make sure that when taking measurements, the line of sight should be perpendicular to the section of armour you are viewing, for instance, the image I used below would be unsuitable for scaling the forearms (Better to use in-game screenshots). Determine your height in mm, then add about 20mm (For the helmet), then scale a reference picture of your spartan model so that the number of pixels = the height in mm You can then use a measuring tool to draw lines against the individual pieces and see what length they should be, and you'll end up with a set of armour that is both proportionally accurate and fits like a glove. I developed a method that worked pretty much perfectly every time. Getting the correct size for all your armour sections right first time will save you a lot of time. There are 2 files for the forearm, I used "Forearm", but "Forearm 2" looks like a better designed model. Armour is scaled for a 182cm person (6.0ft for all ye Imperial Stormtroopers), so just use Pepakura Designer to scale the filles according to your height / stature.
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A much more comprehensive list of my photos is located HERE Since I've spent so long on this project, it's hard for me to list everything that I did to accomplish it, so feel free to leave a comment if you have any questions, and I'll answer it as best as I can! File Download links for the entire suit (+ Hammer and other props): Mega (New link!) Never tried this site before, but they seem more public-download-link friendly than DropBox Also includes an interactive scaling spreadsheet I just made. Pepakura is easier for beginners, but can end up taking longer and is typically less comfortable.
The main ways to go about making hiqh quality armour are either pepakura or EVA foam. To save space I won't detail the required materials (These can mostly be seen from the step descriptions and images), and a good understanding of the safety regarding fibreglassing is recommended. This is my custom Spartan armour from Halo reach Since there are so many pepakura tutorials out there, I'll try and keep the tutorial very basic, and instead add tips and shortcuts that I've found while creating the armour.
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