It helps to pre-curve pieces before glue up. If you mess up, you'll have to cut the pieces apart. When you mate two surfaces they are stuck very well. With contact cement, you don't get any working time.
It's more effective than hot glue, doesn't produce thin strings of glue over everything, and doesn't add thickness. Those lines are a great help in putting it together.
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I printed the templates, cut them out, then traced them in marker on the foam, adding the registration lines too. An angled cut would have been more conducive to the curve of the dome. My joints around the dome were straight cuts, and the joint protrudes a bit, and thus I had to sand it down for a more even finish. An angled cut depending on the curve/placement will get a cleaner joint. My only tip would be to pay attention to cuts/intersections. The template even has registration marks for alignment. Punished Props template makes quick work of building the helmet. I knew what the finish would be on the helmet, and it's decent for foam. A rigid helmet is the best way to get a screen accurate prop with an automotive level finish. I would have liked to use styrene or resin for the helmet, but I don't have a way to shape styrene or a quick way to build a helmet to cast in resin. Tool/Supply List (paid links): pencil (I prefer a lead holder) marker chalk scrap paper for sketching and for protecting work surfaces painters tape duct tape hobby knife with replacement blades metal straight edge cutting mat band saw hack saw file rasp drill with 1/8", 3/16" bits dremel and sanding bit and cutting disk sanding block/220 grit paper heat gun to seal foam wood burning tool to create battle damage in foam sewing machine, black thread, white thread seam ripper rotary cutter leather punch contact cement hot glue/hot glue gun crazy glue wood skewers for stirring contact cement, painting hard to reach crevices black shoe polish paint brushes shop towels respirator with organic vapor cartridges - contact cement is toxic, so is spray paint Total: $418 / I spent $186 as I already had a lot of this stuff Aluminum angle 2"x2" 3/16" Pop rivets 1/8" Pop rivet Snap buttons 1" hook & loop non-adhesive velcro Acrylic caulk Half-time filler Plasti-dip spray paint (2) cans Rustoleum spray paint (1) can each (7 total): satin Chestnut Brown, Flat Red, metallic silver, satin Smokey Beige, satin Oasis Blue, metallic Bronze, stain Granite Acrylic paints: black, white, brown, silver 04 1/2" conduit Wood skewers Aluminum plate 14 ga. Purchase List (paid links): Black coveralls Chelsea ankle boots Black motorcycle gauntlet gloves Industrial safety gloves Face shield replacement EVA foam floor mats (4 pack) Craft foam Leather scraps Grey wool blanket Muslin perm press material Styrene plastic. This is a month of work, working most nights/weekends. I used styrene depending on thickness of the item, including the hand guards and shin armor. I used a sharpie to transfer patterns to the foam, tracing around the paper patterns.
Wait for the contact cement to dry completely before gluing. Wear a respirator! With foam being porous, you'll need two coats to prep it correctly. At some point you will be sanding through the pattern because you need a flat surface. While floor mats are the cheapest option, the EVA foam geared for cosplay can be nicer and doesn't have the imprinted pattern on the back. Everything else, I sketched a template on paper based on reference photos. I used Punished Prop's Mandalorian helmet template. I planned to work from head to toe, because the helmet is the most important part of the costume. I don't have time to sand/prime/sand for that perfect look.
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Plus I know I don't want to pay for a good looking chrome finish like Alclad and it takes time to get an automotive quality finish. I like weathered and beat up props, and they're more fun to make.
I worked from the helmet down, knowing that people would look at the helmet first and hoping they wouldn't look at the boots in case I hadn't finished them. There's a lot of parts and I never have enough time with Halloween being the due date. When I watched The Mandalorian I knew this year's Halloween costume. I've thought about making a Boba Fett Halloween costume for years.
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