I'm always fascinated by pepakura. I love the concept and the end results are often fabulous.
I wouldn't know where to start though. Is there somewhere where you donwload the deisgns or do you create them yourself; I know some designes are downloadable. If you create the design, then what is the process for doing so? How do you keep all the edges and panels so crisp during folding? Is it made of paper or card?
It entirely depends on what you want to make from pepakura. Theres a lot of Halo resources, and various guns, but to my knowledge not much else in regards to cosplay.
To create the design, you need to make a 3d model in program such as 3dsmax, which is my personal choice. And then export that model to pepakura designer which can unfold the 3d model into a 2d design.
That is then printed off onto cardstock, I believe 210gsm is the preferred density, but the closest you can get to that is best. If you look at the pictures and see all those black lines, thats where I've drawn onto the card along the guidelines, meaning it's easier to fold. Basically scored the card.
I should have got a picture of the pages before I started cutting, but this one was 20 pages in size.
Nice work, helemt is always the worst to pep!! :P Now I want to finish my Kat armour for Kita!!