Disney and Marvel’s Big Hero 6 is fantastic for many reasons. One of those is that the heroes design their costumes based on their areas of expertise. It’s all about science. Honey Lemon has serious skills with alchemy, and she builds a purse that allows her to create different chemical concoctions on the spot. She also likes bright colors so her purse is a bold orange with a heart shaped data pad and it’s paired with a pink dress and helmet.
Replica Props Forum user Mitcheg1 started working on a Honey Lemon ensemble for his daughter a few weeks ago. She requested the character. No Pepakura files existed at the time for Honey Lemon’s helmet so he had to create his own pattern:
I started by wrapping a styrofoam head in saran wrap and covering it with clear tape. This allowed me to sketch out the shapes (check out Evil Ted Smith’s YouTube channel for tips on this). I then used this template to create a form out of upholstery foam.
He put that foam onto his foam mannequin head, wrapped it in saran wrap and tape again, and made sturdier templates from EVA foam. He glued the pieces of EVA foam together with contact cement and followed the usual process of filling the foam (he used wood glue and also drywall spackle), sanding, and priming.
He took a break from the helmet to make the dress. He patterned it on a black dress his wife found and then made the Honey Lemon dress from metallic fuchsia fabric. He’s never sewn anything, but you can’t tell from this image. It looks great!
Read more about the process at The RPF.