Parts are cut out and joined with hot-glue. The parts are supposed to be heated and molded to stay in a round shape but I skip this step as I do not have a hot air gun (which I have since purchase one and is on its way here), and the seams tend to be very defined... The basic helmet look like this in the picture. The initial design has 2 slots for the eyes but after trying, they are too narrow to see out. Hence I thought of putting large pieces of black transparent plastic over the whole eye...
The initial design has the back of the helmet cut up a slit and head to squeeze in with the flexible foam opening up big enough... But it was very very hard to put the head into the small opening, and I decided to use this concept instead...
I tried using a hat shade to make the eyes, but they are too thick and in the end, they keep breaking off fro the eye holes... Failure...
Resort to using window solar film to cover over the original foam for the eye (with a opening for the eye to see for each piece).. not good too but gain some experience...
Flaps are also added in to keep the hair and ears in, and not get caught in-between when putting on the back piece...
Also cut some slots to help ventilation... slightly... In the show, these slots appear to be on the piece above this one in the picture...
Finally paste some velvet cloth inside the face area for more comfort.. slightly...
Done! And nope, this is not for me, this is for my little nephew's birthday present...
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