Thanks to Bionicle: Next Generation for the models!
Current Masks Archived
Hall of Fame. Finished Masks and other Bionicle Props by Me and Fellow Bionicle Fans
Numbered has numbers on the edges to guide you, Clean version does not.
Sorry Guys, but I'm removing all download links until further notice.
Oh, awesome! What did you use to make these?
I used a program called Pepakura designer which takes 3d models and allows me to make paper patterns from them.
What materials do I need?
Printer, a cutting tool, glue, ruler and paper. Printer paper is not recommended, too flimsy, cardstock [55lbs or 110 lbs] is preferred.
Can I use thin cardboard?
Sure! It's just a matter of getting the pieces onto the cardboard unless you have a laser printer. The two best ways is either affixing the printed paper onto the cardboard with glue, gluestick, or photo spray mount, OR transferring the ink from the printed paper with acrylic gel medium or acetone (I heard that this method won't work with inkjet printers)
How would I fold the edges?
The best way is to score them. Scoring is basically creating a indented line to help you fold the paper better [no old man wrinkles on the paper, m'kay?] So what you do is you grab either a Xacto knife or a pen and ruler. Line the edge with the ruler and lightly trace with the knife or trace hard with the pen. If you do this, folding will be a lot easier.
I noticed some weird lines inside the pieces, should I cut there too?
No, that's just the program being weird and they're close enough, not like you can cut and glue with nonexistent tabs anyway.. Use your best judgement to determine where you should cut or fold and where you should not.
Great, I finished gluing everything together. Now how do I make it stronger?
This is a tricky question that I can't really answer and best to search cosplay, armor-making, and props-making sites because I'm not quite experienced in this department and requires research on the materials used to ensure health and safety. Several methods exist but I tend to avoid the toxic routes which you will require a respirator that can protect against volatile organic vapors. Things like Fiberglass resin, epoxy resin, etc. fail under this category. Nontoxic routes which I'm sure your parents would rather do are: papier mache (grab a ClearCoat spray so that your work won't be sogged down by the wetness) the hot glue method method (melting a bunch of hot glue and pouring it on the back) or a nontoxic resin like AquaResin.
How would I paint it?
That's up to you! Usually one would have a base color coat, black acrylic paint for weathering and details and silver/light paint for highlights. But again it's your vision.
Hey, can you make patterns for [insert mask name here]?
I'm not the 3d modeler, I get these models from mostly Maphrox or B:NG and I just create the paper patterns. It simply depends if the requested mask has been modeled yet and even then the model needs to be modeled right so that my program can make accurate patterns from it.
Edited by CrunchbiteNuva, Nov 26 2012 - 06:36 PM.