A long length of 1/4" gauge nylon rope.Cardboard, heavy poser board, or chipboard.Heavy-duty tape for paper or cardboard.Magic Smooth and Magic Sculpt from Tap Plastics.Thrift store heavy cotton of denim brown pants.Army Surplus store loose knit cotton undershirt.Also, check out JF custom's foam template post at the RPF, I started with his templates.I have provided my DXF files that I customized and cut to make the helmet and armor for you to download from this instructable.DXF template files made from Pepakura unfolds - also linked to this instructable.(I highly recommend the paid "Pepakura designer" or viewer for the Cameo CNC cutter if you have that machine.) Pepakura free viewer( for opening and viewing 3D ".pdo" files linked to this instructable.Good luck, I hope you will share what you create! Ok, let's get started with Step #1 -the helmet. I will try to find another solution, in the meantime message me if you need these files. DXF templates are here, but it really helps to compare them to the 3D pepakura model. I'm having difficulty attaching the pepakura files to this instructable, but all of the. Freehand template making and cutting for adding details and modifications to the Pepakura template designs.Heavy-duty angled cardboard scissors work great for these parts if you don't have access to a CNC cutter. Also not for everybody, as a laser cutter can be hard to come by.Laser-cut EVA foam, cardboard and chipboard.The torso armor template is 18" x 24" because I cut that on a machine with a large bed, and the parts are large, so I left that at full size and you can edit the parts in Inkscape to fit on multiple sheets if you need that. I have created most of my templates at 12" x 12" for convenience for those who use Cricut or Silhouette cutting machines.I would recommend trying out my Cardboard Batman Helmet Instructable first to see if creating with Pepakura is for you before attempting a whole suit.Currently, seems to have a decent collection. Sometime finding pepakura files online can be tough, as pepakura websites seem to go up and down. I like using this method because I can find templates online, modify and easily cut them with CNC cutters or scissors. Pepakura is not for everybody and it takes some patience.Techniques I used: (I used some fancy-schmancy cutting tools, but everything can be cut by hand) I have uploaded the patterns that I used to create this exact costume, but I've also attempted to describe how you can modify or create your own templates and designs to create your own mash-up. I created this fantasy/ medieval/ viking costume so I could justify a bearded batman when my family took me to comic-con for my birthday and we all created bat-family mash-ups. One of my all-time favorite creations is my custom batman costume.
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