Project W001 - STEP 3 - Cutting The Parts

STEP 3 - Cut ALL the things!

It should go without saying, but now you have to cut all of your pieces out. BUT WAIT!!!

We did that the first time we made parts of this project. We printed out all the parts on regular paper and cut them out then glued them together. The end result looked like these -

 

While still functional and highly detailed they don't have much structure and can't hold up their own weight. But they don't look bad

 Problem here was the scaling was completely wrong. This helmet was suppose to be a few CM larger than my head so I could put padding and fans in. Turns out it was a lot more than originally expected. So a lot was learned and this prototype was scraped. This version was scaled to 340MM when it should have been 310-320MM to fit properly.

So back to Pepakura Designer and try again. After some further searching online and testing other helmets in the source files we found a simpler version with the W crest as a removable unit. We printed this using the new scale of 280MM and cut it out.

Before we started cutting each part out we glued the parts to Foam Sheets.

Not ideal for this project but it's all we had available right now. We had to glue a few sheets together at the edges so we could cut out larger parts so we used hot glue for these.

After we let the glue dry, it was time to start cutting!!!

Since we were using the foam as the base instead of just paper we cut the "tabs" off the parts as we went along and used tape on the back of the parts.

HINT - parts are numbered, just match the numbers edge to edge

After a while we got these -

Much stronger and properly scaled.

Problem here, while it fits as expected it's still not very strong and ventilation IS a problem! Once the eyes go on it'll be really hard to breathe and not get over heated.