- Computer with Pepakura Designer 4
I use a program called Pepakura to make most of my foam armor. The program can take 3D-models and unfold them so they become flat and can be printed out. These flat pieces can then be cut out of your desired material, and glued together. There are plenty of Youtube tutorials on how to use Pepakura if you want to look further into it, but the best thing is to get in there and practice!
This is how the program looks ➡️➡️➡️
You can get the finished 3D-model from Cosplus 3D's Etsy shop here: https://www.etsy.com/no-en/listing/716539921/saiyajin-hair-pepakura
On the left side you can see the 3D-model and on the right you can see all the parts folded out flat. This is also what will be printed out. It might seem very chaotic, but having the program open on a computer where you work will make it much easier to put together. There are a lot of parts, but it is laid out quite systematically, just don't let it overwhelm you!
Once the paper is printed, cut out the pieces. I organized the printed out paper the same way as the program organized it, like shown on the right. Then you can just click on the 3D-model and highlight the part that you are looking for and a red square will pop up on the right side, indicating the part.
Use a sharpie to mark the foam and start cutting! Put the paper cutouts on top of foam for each piece, and after marking every piece, cut them out. Lay the foam pieces out in the same pattern as the paper pieces where laid out.
I used a scroll saw to cut out the pieces, but you can just use a sharp boxcutter knife. To make it easier to glue the pieces together I used 45° cuts on all of my cuts.
The image on the right shows an example of where to do the different cuts. I used cliff cuts on the spikes connected to other spikes and hill cuts at the base of the spikes.
The part highlighted below is hill cut all the way around.
I used contact cement to glue the pieces together and always made a new part that would connect to what I already was making. Making sure I got the angles right and going back and forth from pepakura and and cutting. Slowly building up the wig.
The small hair spikes closest to my ears only consist of 2 parts, a front and a back. I used 45° cuts on those as well, but you can just make them out of one solid foam piece. Do a little sanding and dremeling(150 grit) on the seams and you got yourself a foam wig!
Seal it with your preferred sealer (I used hexflex) and you are done.