Here's how I made my helmet for my Big Sister from BioShock 2 cosplay:
This took a long time to complete with about 18 hours total of work put into it.
- Big rubber ball
- Paper Mache mix
- cooking oil (PAM)
- craft foam
- EVA foam (floor mats)
- small can of cat (or dog) food
- hot glue gun
- small sheet of plexi-glass
- Rustoleum spray paint in chrome and hammered dark brown
- cheap acrylic paint in gold, silver, black, and teal
- 6yd polyester filler cord
- school glue
- Mod Podge
- exacto knife
and most importantly, a reference! Like this one:
The newspaper was ripped into strips, the Paper Mache was mixed, and the rubber ball was sprayed with cooking oil (this would allow for the ball to be popped and removed easily, without damaging the Paper Mache form):
The newspaper was dipped into the Paper Mache to cover the ball in layers (letting it dry between each layer). There are six layers total, and each layer took about a day to dry, so it was a pretty lengthy process:
The neck and port holes were then drawn and cut, out using an exacto knife.
Using EVA foam and a compass, the rims of the portholes were made, and cut out using an exacto knife.
'Metal' panels were made using craft foam, and each piece was lined with polyester filler cord to create a 'welded' look. A cat-food can was also hot-glued on a piece of EVA to make the lamp:
After sealing the foam details with several layers of a Mod Podge/water solution, everything was spray-painted chrome.
Everything was then spray-painted with a hammered dark brown, and the 'welded' details were painted silver. The port-hole rims were also painted gold. Plexi-glass was cut to fit three of the port-holes, the smallest one was left empty to act as a breathing hole. The plexi-glass was covered in red cellophane.
Finally, an exacto knife was used to make it look 'battle-damaged', with scratches around the entire helmet. Black paint was then painted on and wiped off to make it look grimy. The fish on the back were painted with cheap teal acrylic paint.
That's it! It's not yet one hundred percent completed, as it's still missing a few details (wire hose and hexnuts around the front port, glass hasn't been glued in place, LED's need to be installed etc) but other than those few, small details, it is complete! I'm really excited about how this came out, and can't wait to start working on the other pieces of this costume!