It took me two evenings of solid work to produce the card model. I began with the crown and worked my way downwards carefully cutting out the sections and gluing them together with general purpose glue. I used yellow card since that's what I had in stock. It's basically greeting card thickness, quoted in Europe as gsm, I don't know the US equivalent. I use standard card for this, it available at any good stationers or office supplies retailer.
After you have downloaded the PEP file, use Pepakura to print it out onto card stock. No big deal, just shuffle the bits around. I didn't really finish it to a high standard, just painted it up with all the facets still in place. I made a Master Chief Helmet from Halo a couple of years back for a space girl shoot.
