Introduction: How to Make a Batman Cowl From Paper
This project will show you how to make virtually any mask/ helmet you want out of paper. For this example, i will be making Batman's cowl.
Supplies
Printer paper (cardstock is better if you have it.)
White glue Scissors or exacto knife
Pepakura Designer https://tamasoft.co.jp/pepakura-en/
Optional:
Fiberglass resin
Fiberglass sheet
Some kind of body filler
A brush
Sandpaper
A high quality spray gun
Automotive filler primer
Step 1: Find Your Desired Template
A simple google search for "Batman cowl paper templates" will give you thousands of options to choose from. Most templates show you a picture of what the final product will look like, I try to choose the best looking ones.
Link to the template I chose: http://www.papercraftsquare.com/batman-cowl-mask-p...
I chose to make the option without the neck.
After the file is downloaded, open it in pepakura viewer
Step 2: Print Your Template
Hit ctrl+p on your keyboard or navigate to print in the file section of pepakura viewer.
You can adjust the size of your template for a custom fit if necessary.
Make sure that your print setup is set to landscape otherwise your templates will not be to scale.
Print in black and white for best contrast.
Step 3: Begin Cutting Your Template
I would recommend getting a pair of high quality sharp scissors. This will make the cutting much easier.
You are going to spend at least a whole day cutting these templates out (in my case it was two days) so throw on your favorite show or playlist and get comfortable.
Make sure you are as careful and precise as possible.
Step 4: Organize Your Cut Templates
I like to lay all of my cut templates on the floor in my room. Try to put similar looking pieces by each other for efficiency later. I put the biggest pieces closest to me and the smaller ones further back.
Step 5: Begin Gluing Your Templates
This part is the most difficult. I have the program Pepakura Designer open on my computer while i am gluing. You can click on the template in Pepakura Designer and see the corresponding piece it glues to. The piece will be highlighted in red in the program. If you look closely, there are tabs of paper on the templates. The tabs are where you apply the glue. The tabs line up perfectly with the correct templates.
Step 6: Optional Hardening
If you just want something to display in the house, I recommend putting the finished paper cowl on a styrofoam head and stopping here.
I like to go a bit further and harden the cowl with fiberglass. If you are like me and want your cowl to be more durable then you will need fiberglass sheet and fiberglass resin.
Step 7: Fiberglass
You will most definitely need a respirator and a pair of disposable gloves. Fiberglass resin fumes are not something you want to be breathing. This part is messy so lay down some cardboard and grab a brush. I like disposable brushes because it is very hard to clean resin off of the brush. Wide brushes are better for applying the fiberglass.
Cut the fiberglass sheet into 2 inch squares and make sure you have plenty of them. You will need more than you think.
When applying, brush a thin coat on the desired spot on your cowl. It is important to be gentle as we are working with paper. note: You will want to apply the fiberglass to the inside of the cowl.
Once your base coat is applied, place a piece of fiberglass on the still wet resin.
Add more resin to the fiberglass sheet in a dabbing motion.
We don't want to brush it on because it will pull the fibers apart
Step 8: Trimming
Once your cowls inside is completely covered in fiberglass, Let it harden for 24 hours.
The hard fiberglass will be protruding from the neck so you will want to trim it.
I used wire cutters for this because fiberglass is too strong for regular scissors to cut.
Step 9: Adding Filler
You will want to lightly sand the outside of your cowl with around 80 grit sandpaper. The rough surfaces allows for a stronger bond with the finishing putty.
If you don't want to sand as much, you can buy a putty that is easier to sand. Personally i like harder putty's because they give a better finish. Popular brands like Bondo work great.
Step 10: More Sanding
After your coat/ coats of filler is applied, you will have to spend a very long time sanding. If your putty is hard like mine, you will need to start with a rough grit and work your way down until you get you desired finish. I ended up stopping around 400 grit.
Step 11: Priming
You're now in the home stretch. use a high quality primer for the best result. I opted to use automotive primer because it acts as a thin filler. This allows for an even smoother finish. Apply the primer in thin even coats with a spray gun. Make sure you use a high quality spray gun so as to get a clean spray. To avoid runs in the primer. If you want, you can hit the cowl with another bit of light sanding. This will reveal any high spots you can sand out to get an even smoother finish.
Step 12: Paint
This is it, you're almost done. Choose the colors you want, I actually ended up liking the finish of the primer. The finish i got was more rough, I don't really like the perfectly smooth look. Apply the paint in the same way as the primer. Even coats. Once your paint job dries, if you want an even more realistic look you can dry-brush silver paint on the spots where you think would be damaged. In the interest of saving time i wont show how this is done, as there are hundreds of tutorials online.
Step 13: Finished
Enjoy your finished product, I would recommend putting it on display.