Originally Posted by dbchan
I would suggest making it out of craft foam pieces ( or wonderflex, or worbla, or anything semi rigid that comes in a sheet, really) , heat shaped around the existing visor. Using clay for something with such simple, flat pieces and sharp angles would be unnecessarily hard and heavy.
well the last time i tried thermoforming it wasn't good at all, i even cut myself trying to do it. I was planning on using a pepakura file for the main component of the mask the main reason i was thinking of using molding clay was so i could give a nice and smooth and easy to paint surface. Any other tips?