OK, so here's the skinnny. I printed out WOF's templates for a Boba Fett helmet at 100% and .25 " margins. Digifett & SD68's helmets were made using thin plastic and For Sale signs respectively, both of which I believe to be 1mm thick.
When I built the helmet out of 3mm sintra, the parts did not match up well. I think the problem is my material is thicker than what the WOF templates were designed for.
How do I compensate for the thicker material?
Should I just print the templates out at more than 100% like say 105% or more? I'm sure someone here has run into this before.
Thanks for your help.