Working with resin fiber resin can be hazardous and not everyone has access to a vacuum form machine. While Shawn's final costume is impressive, it's certainly not cheap. ![]() Shawn's Full Scale Space Marine Costume Debut at Maker Faire 2012: After cutting away excess plastic, a bit more sanding, and spray painting, his costume was complete. Once Shawn was done, he went a step further and vacuum formed the fiber glass parts, creating a hard plastic shell. As a result, Shawn and anyone else going down this route will have to spend a considerable amount of time sanding, applying more resin, and sanding some more until the surface is smooth and round. The problem with a glued Pepakura model is that it's sharp and angular, which isn't good for a costumes that are supposed to be round and smooth. He then glue them together and reinforce the card stock using resin fiber resin. ![]() ![]() Shawn loaded those PDO files into Pepakura and printed out 2D cut outs on card stick. A member on the Obscurus Crusade had created PDO files based off 3D models from Relic Dawn of War game. ![]() On June 4, 2012, Shawn Thorsson posted a step by step instructions ( link) on how to build a life size Space Marine custom using Pepakura Designer, a program developed by Tama Software, which allows creating paper craft models from 3-dimensional data.
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