This is the helmet I want to build. I’ll use different colors for it, but the model is the same.
After I cut out the craft foam pieces I trace their outlines to the thermoplastic sheets. I usually cut a 1cm wide edge which will be folded to the other side of the craft foam piece. It saves a lot of material.
I prepare the upper head piece, heat the thermoplastic base and the press the craft foam on it.
I recommend to work with all parts step by step. Do not cut your thermoplastic and heat all the pieces already. You better work with it as long as it’s warm and re-heating the thermoplastic can cause lot of bubbles. I try to avoid to re-heat bigger surfaces while working.
Placed all the details here with your thermoplastic. Now we move to the next step.
Preparing the Orc face mask.
For the ponytail I bought false brown hair and cut a thick piece.
Tied it down and then burnt one end with the heat gun to glue all strands together.
Looks messy, but it’s tight and no hairloss is garanteed.
The ponytail will is wrapped in a piece of thermoplastic/foam, which is attached to the helmet at the back.