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Animatronic Stargate Helmet

stargate helmet 1

One of the most striking aspects of Stargate is the impressive designs. The helmets the members of the Horus guards (Jaffa guards serving Ra) were especially beautiful. Instructables user Honus was inspired to make a version as soon as he saw the movie and sketched multiple designs over the years. He finally got around to building an animatronic version of the headpiece and wrote a tutorial so that it can be replicated by anyone with basic hand tools. He provides Pepakura files for the helmet and a thorough listing of necessary supplies. Here are the basics on cutting cardstock to form the helmet:

The best thing I’ve used for cutting the cardstock are small, sharp scissors. Only cut out as many patterns in one sitting as you are comfortable working with. This will avoid a lot of confusion and the possibility of lost patterns. Once you’ve got some patterns cut you’ll want to fold on marked lines. Pepakura uses a regular dashed line for mountain folds and dashed/dotted lines for valley folds. Pretty simple really.

The best thing I’ve found for folding lines is a small 6″ long steel ruler. It’s long enough for large areas but small enough for small folds when you use the end of the ruler.

Once you’ve got a few pieces cut and folded glue them together on the numbered mating edges. I use Aleene’s clear gel tacky glue and it works great. Just hold the edges together for a bit until the glue sets and move onto the next edge. Some of the folds are tricky and it can take a bit of fiddling to get pieces to fit together properly!

stargate helmet 2

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