A student in one of my recent Mini Nuke classes asked if I knew how to build a folded paper Halo ODST Helmet. I'd never done Pepakura before, and decided to give it a shot!

All told, assembly took me about 4 hours. I highly recommend getting the parts laser cut. Having the guys at Hammerspace cut these for me cost less the $15 and saved days of work. Check out their Digital Fabrication Services if you need something cut on the laser.

A few quick tips withe process of Assembling a Pepakura Model.

Use high quality cyanoacrylate glue (super glue). I prefer Zap-A-Gap. You can find it at any true art supply store. Good super glue sets fast and keeps you moving through the model
Work with the model open in Pepakura Designer. The logic of the parts is non-intuitive and selecting a face in the model will highlight the part you need on the layout.
Your hands will get covered in Super Glue. There is no way around it. When you're done working, or you fingers get too curtsy to proceed, use an Acetone soaked rag to clean your hands. The Acetone will break down the cyanoacrylate and make it easier to remove with soap and water.

If I were to proceed with this model, the next step is to coat it in Fiberglass resin, which will harden it, then begin using bondo to smooth out the facets. I'm not committed to that part of the process, so I will likely just leave this in its current form as a display piece to illustrate the Pepakura process in the Hammerspace collection.

This file came from the 405th Pepakura Database. You'll need to create a login with them to view/download them.