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Message: <blockquote data-quote="xero" data-source="post: 188300" data-attributes="member: 674">Stepping in for a moment, as I have been researching all this stuff for a long while due to interest in Halo helmets, Fett, and Daft Punk... The general answer for this is "card stock". Card stock, however, comes in a variety of thicknesses, just like normal paper, and can also be bought in various sizes.For my Daft Punk helmet I am working on, I am using 110lb cardstock, sized at 8.5"x11". I got 100 sheets or so in a package at Walmart for about $5. This should be more than enough for a few helmets.I've also heard -- but not seen -- of cardstock in the 130lb weight range (!!!) and in A4 sizings. Again, heard, not seen. I wonder if the 130lb weight would jam a printer...In any case, with careful folding, and plenty of careful work after the assembly (resin coat, fiberglasing, bondo'ing, etc) you should come away with a good helmet using 110lb card stock.</blockquote>

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