FYI: Hot Glue Still Burns
I finished cutting out all of the pieces for the helmet. My goal is to get the card stock all glued together before Thursday. We'll see if I can make it or not.
I started gluing the pieces together last night and while this design has fewer overall pieces, the cuts are MUCH more intricate. There are many more curves to this piece than the rest of the suit.
I don't have any more pictures yet, so you'll have to imagine them glued together.
To date I have the Helmet, Chest, and Back printed with only the Helmet cut out. Here are pics from the models:
I haven't gotten any bad hot glue burns yet, but I do expect that there will be some.
My plan right now is to finish the helmet pepakura, fiberglass it, and get at least a few coats of Bondo on it. I will likely save all painting to do at one time so to reduce the amount of fading and inconsistencies between pieces. Here is the order that I am thinking:
- Helmet
- Chest/Back
- Shoulders
- Upper Arm
- Forearm
- Thigh
- Shin
- Boots
- Hands
The Abs section is going to prove tricky. This process with fiberglass/Bondo produces a rigid piece. Possibly not ideal for sections that may need to bend or flex. I do have a few tricks up my sleeve for how to accommodate this movement while using stiff pieces.
I could go the EVA Foam route, and still might, but I think I can make this work. Also, stay tuned for the suit under the suit. Still quite a way off, but I have ideas!

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