Tag Archives: Craft Foam

Level 5-2: Attach Accessories

18 Jun

Is that a club on your hip or are you just happy to see me?

With Subject Delta’s suit near completion, it was time for some finishing details! What’s a suit without accessories?


Subject Delta Action Figure Front

If you’ll notice in the reference above, there’s a club of sorts hanging from Delta’s hip. It appears to be a wooden cudgel, the kind akin to a tire thumper like truck drivers use to check their tires. Delta and the Big Daddies use theirs to check underwater pipes.

For the shaft… Ha! I said shaft… we used a 3/4″ inch dowel rod. I cut the length to about 12″ and then cut one end with a series of angles to form a rough point.

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                                                                                                                                                                                                                                                                                                                     I then sanded the rough point down to a smooth, rounded knob… HA! Knob, this is too easy… and then sanded the opposite, flat edge to round the edges just slightly.  Next, I created a hand guard using a wooden napkin ring and a crafted foam piece.


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 The foam piece took some finagling as the template for a circular trapezoid; or cone without a top, is actually a rainbow shape. Using 2 mm foam, I cut out the rainbow piece and a circular doughnut for the cap. I glued them together with hot glue and attached it to the wooden napkin with hot glue as well.


Look at how nicely that fits! You’ll also notice that there are a series of rings notched into the handle of the club.  I free-handed the rings with a pencil and then used the hand saw to cut about 3/8″ into the handle to create the grip. With the basic pieces complete, it was time to give them some color. For the club itself I used a dark walnut stain. I painted the stain on with a paint brush, let it set for 2-3 minutes and then wiped it off with paper towels.

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For the hand guard, I coated the foam piece with a few layers of shellac and then hit it with some of the Antique Brass spray paint.


After the pieces dried properly, I fixed the hand guard in place with a bit of wood glue, used some black acrylic paint to weather it and viola! Finished Big Daddy, pipe-thumping club!

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To attach the club to the suit, I fashioned a sort of holster out of some of our left-over leather. I started by cutting a rectangle section to serve as a base. I stitched the piece like we did with our straps for consistency. I then cut and stitched another, longer and wider rectangle and attached it to the first to form a leather tube. I hot glued the pieces together and spot stitched them for added strength. I then hot glued the combined holster to the suit along the edge of one of the straps and spot stitched it as well.

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Sara suggested gluing the cudgel into the holster. She was worried that it might fall out and I, with my mobility limited in costume, might not be able to put it back in. But, after reading over the C2E2’s weapon’s policy, I wanted to be able to remove it in case security wanted to take it away. Shows you what newbies we were, worried about a small wooden club. Ha! Ultimately, we didn’t have a single problem.

The other element you’ll notice from the above shots, is the elbow pad. I built one for the non drill arm and two similar, slightly larger pads for the knees. I started off with a basic elbow/knee pad from Home Depot. The pads were an ideal base; sturdy and durable with a built-in elastic strap. They were a perfect anchor to build onto. One edge of the pad is flat and the other rounded; but if you’ll notice, Subject Delta’s pads are rectangular. So, I took out my handy-dandy hand saw and cut off the rounded edge.

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With the pads cut to the proper shape, I measured and cut out a strip of leather to face them with. Before attaching the leather, we hand stitched it with some of our yellow detail thread. I then hot glued the leather to the pads, around the sides and anchored the edges around the backside cutting slits at the edges to allow for the elastic strap. To finish off the tops and bottoms of the pads I stood the pads on end and traced the shape to get perfect curved shapes to hot glue in place.

knee pad IMG_0626

The next step was to build the metal platting attached to the pads. I used some 2 mm craft foam and cut out three rectangle pieces with curved edges to match the shape of the pads. I then used the hole punching tool from our grommet set to punch out some foam circles to serve as “rivets” for the corners.


I hot glued the ‘rivets’ into place, sealed the foam with a couple of layers of watered-down Elmer’s glue,  applied a few layers of Shellac and then sprayed the plates with some of the Antique Brass spray paint. Once the plates were complete, I hot glued them to the pads. Sadly, the hot glue was not strong enough to adhere the plates to the faux leather pads. So, I pulled the plates off and peeled off the useless hot glue. After a couple of days of brainstorming and trying to figure out what adhesive would work best, I remembered the stuff I used to reattach the soles of my sneakers… SHOE GOO!!! This stuff is amazing and I plan to use it for this and future projects. Since it’s made for shoes, it’s perfect for adhering wildly different types of materials together. It’s perfect for attaching more substantial elements to fabric pieces while still remaining playable. You just smear the stuff to both sides of whatever you want to glue together and let it sit for a while, get good and tacky and then put it together. We let it cure for 24 hours and it worked perfectly!


After all of the plates had time to properly dry, I then took some of our black acrylic paint and weathered them.

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Last but not least, I detailed the suit. I laid it out on the floor and took some time weathering it with some of the black acrylic paint. I made sure to grime up the zippers that ran along the outer seam of the legs, as well as all around the strapping and patches.


What started on a pretty basic work-suit and now, after some dressing and distressing, we’d wound up with a pretty fantastic looking suit!

Photo by: Geek Behind the Lens Photography

Photo by: Geek Behind the Lens Photography

Thank you for following along as we crafted Subject Delta’s suit! — TCG

Level 3-2: Refine Weapon

26 Nov

They say that you make time for what’s really important, but I don’t think those guys that said that had the months of November and December in mind. Those Crazy Gilberts are playing catch up in a major way and here we are, merely days away from Thanksgiving, Daniel’s birthday behind us and a whole boat load of things left to build. Don’t worry though; I remember where we left off and I won’t leave you hanging because I’m sure you’re chomping at the bit to know how Subject Delta‘s drill is coming. Aren’t you?

Subject Delta's Drill Pre-CuttingWhen we last left the drill project, we have something that looked a lot like a crude, Christmas tree made out of Legos. Our next step was to trim and glue them together but how would we ensure that the blades would taper at the correct proportions? For a split, foolish second, we considered free forming it; just trusting the scissors and the foam and the universe. But then we came to our senses! Once again, Daniel’s tin foil trick came in handy.

Daniel positioned the foil and then I came in and traced it out. What’s great about using the tin foil is that it’s easy to re-position and bend into shape. It’s a very forgiving and cheap tool.

foil cutting foam guideTraced Line on Drill Blades

Snip, snip and we’re set to move on.

Foam Drill Blades CutFor our next couples activity; hot gluing! One of us would lay down a line of hot glue while the other would follow and smoosh the foam together to make our blade shape. Since my hands are so teeny and delicate, Daniel got the job of smooshing our foam together. Then, we went in and added layers of glue to the base of the blades, adding some more strength to their structure. We also used the tip of the gun to smooth out the seams between the strips of foam to give it a more uniform look.

Subject Delta's Drill  Foam Blade


Subject Delta's Drill Foam Front View Subject Delta's Drill Foam Blades Side View

Now all that’s left is the small, hardly time-consuming papier-mâché step. And by hardly time-consuming I mean horrifically time-consuming. Not only did Daniel insist on medium size strips of news paper strips cut to the curvature of each blade, but he also took hundreds of tiny, thin strips of newspaper to line each edge of blade. In case there’s any doubt of Daniel’s dedication to this project, take a look at this.

Scale of  Papier-mâché Drill Blades  Papier-mâché Along Drill Blades

Allow me to quote myself, “It finally happened. 11/10/2013, 10:04 PM. Daniel is sick of paper-mâché.” – Sara; Facebook.

Daniel looked over at me, his fingers coated in glue, his back aching from hunching over the drill and he said, “Whatever we build in the future is gonna depend on how much paper-mâché it needs.”

Subject Delta's Drill Blades Paper Mache

But was it worth it? Take a look at this and tell us what you think.

Subject Delta's Drill Blades Finished

The holiday season is rushing in, ready or not, and bringing with it new gaming consoles, games, gatherings with friends and families, meals and treats that require time in the kitchen and the days are certainly not getting any longer. I was thinking today about how I would possibly find time to play a new game I got over the weekend and a this question came to me; how do cosplayers find the time to consume the things that they wind up cosplaying? How do you, our fellow cosplayers, find the time to invest in new fandoms, or get to know new favorite characters that you’d love to pay homage to, how do you balance everything?

Seriously though, any tips on time management and motivation are greatly appreciated! — TCG

Level 3-1: Acquire and Assemble Weapon

12 Nov

Subject Delta and Eleanor Lamb Helmets

While it’s not quite as epic as we would have liked, here’s your picture of our hard-won Subject Delta and Eleanor Lamb helmets!

As fun as this stay in the land of Bioshocking helmets has been, we’re more than pleased to leave it for a while. The weather has changed here in Chicago and the weather conditions are no longer conducive to Shellacking in our nasty back alley. That and the painting will have to wait until Spring. Yes, you heard it folks this post is going to be about something other than port holes and cap nuts and tubing. This post is about our hero’s signature, gut-grinding weapon of choice; Subject Delta’s drill.

Subject Delta Drill Reference - Action Figure

This beefy bit of machinery dished out all sorts of grisly ends to many a Splicer down in Rapture and now it’s our job to bring it to life! While this picture give you a great impression of what it should look like when it’s finished, Daniel really likes this reference photo we found so we’ll be putting a little TCG style to use while working from this particular reference.

Subject Delta's Drill Reference

As we prepared to begin work on the drill we batted around a lot of ideas. Daniel’s original thought was a run of the mill traffic cone but I was worried that it would be too heavy to lug around all day with one arm. So then we thought of a floral arrangement cones but we couldn’t find any that were big enough. I even thought about making it out of thin cardboard, but Daniel kept going back to that darn cone. He almost swiped one right off the street. But that would be gross, so instead he bought one at Home Depot and he won me over. This would be our base.

Traffic Cone

What would the drill be without a tip? We glued a little Styrofoam cone to the top of the cone and then, like most of our low-budget cosplay, our next step was papier-mâché. We wanted to cover the plastic of the cone in a layer of papier-mâché so that the blades would have a solid anchor. We knocked that out together in under an hour, then we sealed the Styrofoam with some Elmer’s glue and then we had our drill’s base situated and ready to go.

Styrofoam on Cone Cone with Paper Mache

Drill with Weatherseal

Next, we needed to mark the route of the blades that spiral the length of the drill. To help us map it, we took some yarn and wrapped it around the cone so that we could trace it. Then we applied Daniel’s new favorite material; rubber weatherseal. It wrapped smoothly and seamlessly around the cone and the adhesive bottom worked like a charm. Again, in no time at all, we were finished and ready to start the real task; attaching the blades.

This might shock you, but we had differing ideas about the best way to do this. In fact, we had several arguments verging on the edge of nasty fights about it. But, in the end, Daniel’s idea prevailed and I couldn’t be happier with the results. Since it was his grand design, I’ll let him tell you about it.

For the drill blade, Sara came up with this great idea of sandwiching bendable, shape-able wire, like pipe cleaner wire, between two strips of craft foam and gluing the strips together to make stiff but bendable strips of foam. I liked this idea. But then it dawned on me that, while this would be a great idea for circular bands like a bracelet, it still wouldn’t allow flat foam to contour to the circular, spiral path of the cone without bowing and bulging at the edges. We tossed around  a few different ideas until we settled on a sort of foam tent.

Pile of Craft Foam for DrillFoil Measuring TrickIn preparation for the build I spent the better part of an evening cutting a rather impressive pile of 1 1/2″ wide by 3″ long foam strips. I then used my trusty strip-of-foil-method to figure out the exact shape of the curve on the cone and cut a handy-dandy template. The template could then be used to quickly trace and make more mini foam blades.

Sara set to cutting out the curved sections of the strips using said handy-dandy template while I set to hot gluing the strips of foam we already had; one on top and one on bottom of the rubber weatherseal.

Making Subject Delta's Drill Blades

Unfortunately, I forgot to mention to Sara that the template I made was for the curve only and not the height of the blades we needed. The example on the left is how she cut them, the example on the left was how they should be cut. The result was a was quite a few skinny, wasted strips; around 24 to be precise.

Blade Template Mix Up

After a bit of grumpy finger-pointing we each accepted our share of the blame and moved on. Luckily, we had plenty of strips to spare.

As good as my handy-dandy template was, it wouldn’t work for the entire length of the cone. So Sara cut  new templates as the moved up to the skinnier parts and eventually all the way to the top of the cone. This resulted in a big range of shapes and sizes for us to use. As I went, I would trim the edges of the foam before I glued them so that they would lay flat side by side. It was tedious but the results were rewarding.  — Daniel

Foam Blades in Pieces Piecing Foam Together

Once we finished this step, we had ourselves a very lovely, albeit crude, Christmas tree, cone, thingy.

Subject Delta's Drill Pre-Cutting

Of course, we’re still talking about baby steps here. There’s still a long way to go and C2E2 is looming ever closer. Just because it happens “next year’ doesn’t mean we have a whole year to go! We’re trying to build and maintain that momentum but will it carry us through the holiday season? — TCG

Level 2-6: Regroup to Progress

5 Nov

Eleanor Lamb's Helmet and Harness

Now for the second half of our Saturday night Work-a-Thon and beyond! While Daniel was working away on Eleanor Lamb‘s helmet, I was busy with the harness. Even though it’s not the flashy, hardware speckled spectacle that Subject Delta’s harness was, Eleanor’s harness posed its own set of difficult intricacies.

All that I needed to do was attach a foam liner along the outer edge which might seem like a simple task until you take into account the imperfections in the proportions of the frame. Sure, building these on ourselves made for a snug, customized look, but like most bodies our are asymmetrical. In other words, we’re crooked and crooked is difficult to line in ruler straight strips of foam. The front was no problem but the back, oh boy, the back is where I ran into some hangups.

Eleanor Lamb harness and helmet 2 backThis is a decent angle for you to really see the hump on the back of the harness which, at a glance, doesn’t seem like it should be too much trouble. Until I laid a strip of foam along the edge, I didn’t think it would be too bad either. Foam Lining on Eleanor Lamb's harness

Until I discovered that I would have to “Frankenstein” the strips of foam together with little cuts and hot glue. It took about four different pieces of foam in an 8 inch section and then three strips on the other side. It was a hassle but it was satisfying!

Foam Lining on Eleanor Lamb's harness

While this may be hard to believe, in all the months that we’ve been working on this project, this was the first where we both needed the glue gun at the same time. And instead of going out to buy a second glue gun, like normal people, we decided to share it. And by share it, I mean sliding it back and forth to one between opposite ends of the wooden board we were using as a single work surface. I’m sure it was both amusing and adorable. We’ve been told we’re adorable.

The fruits of our night’s labor looked something like this:

Eleanor Lamb's helmet Crooked Harness

Notice anything askew? Aside from my looking like I have a brown mustache, that harness is incredibly crooked. At first, we wondered if this was because of the way I was standing but, sadly, the bright yellow lining made clear our mistake but we had to wait until the next day to fix it.

Bright and early the next morning, before I even brushed my teeth, I was up and working. Daniel went to go get breakfast but, before he left, I had him take a couple of reference pictures. Turns out the source of the problem was a big freaking gap between my left shoulder and the harness. Looks like I might have had some major tension in that shoulder while Daniel was building the frame.

Crooked Harness Front ViewCrooked Harness Side View

So I whipped out the old glue gun, cut some strips of 5 mm craft foam and made some foam pads. The difference was amazing!

Harness Corrected Front Harness Corrected Side View

And with that little hitch out of our way, we were just a short sprint away from completing the harness. But while I stretch in preparation for the 10 yard dash, Daniel’s going to tell you about his new favorite product.

Rubber Weather SealRubber Weatherseal!!! It’s made for doors and windows but, man, is it my new favorite material to work with. It comes in a variety of shapes, has its own built-in adhesive strip and is made of durable, flexible rubber. How can you not love it already?

I came across this little gem while perusing the aisles of Home Depot in search of something to use for the seam work on Eleanor Lamb’s helmet. We sketched out the shape of the seams using one of our black markers, cut the pieces to fit, peeled off the self-adhesive backing and laid them in place.

Easiest step we’ve had to date!

This stuff was also really easy to cut a piece together into nice, crisp corners. It also bends quite nicely to allow for smooth curves. Great stuff!!! Can’t wait to find other uses for it as we proceed with this and other cosplay projects. It’s easy to work with, yields great results and makes what would other wise be a painstaking detail process a snap. And look at those results. — Daniel

Eleanor Lamb's Helmet Back View

And we’re always thankful for an affordable product that saves us time! You can also see that we added the little port holes to the back. Just like Subject Delta’s helmet we used plastic insulating bushing rings, found from the plumbing section at Home Depot. They come in all sizes which lend a bit of consistency as we moved from size to size between the two of our helmets.

Next, we applied a second layer of the 2 mm craft foam to the edges of the harness, a bit of that magic weatherseal, a couple of those wire rope clips, seven wing nuts and the harness was all set! This was a very quick step since most of these materials and processes were used on Subject Delta’s helmet.

Eleanor Lamb's Harness front view

The next to last step concerns the little panels you see running along the top of Eleanor Lamb’s helmet between the main porthole and the “little hat,” as we’ve taken to calling it. We decided to make these out of 2 mm craft foam strips that would be glued to the helmet and tucked beneath the flex tubing that runs between the porthole and the little hat.

helmet ridge stripsDaniel cut, positioned and then trimmed with the X-acto knife each individual strip. He then glued them into place being careful of the spacing not only between each strip but between the two rows as well.

Ridges on Helmet FinishedWith most of the details now in place, I cut a couple of rings out of 5 mm craft foam, Daniel slapped some wood glue between the layers and voila – we’ve got ourselves a bonafide Eleanor Lamb helmet!

We attempted several selfies so that you guys could get an epically awesome picture of the two for us in our helmets but none of them met our high standard of Bioshocking awesomeness. So we’ll get that together for you all to enjoy in the next post.

Until then, any Chicago readers picked up their C2E2 tickets yet? The count down on their site makes this very, very real. Whoa!! — TGC

Level 2-5: Split Up to Cover More Ground

28 Oct

Absence makes the heart grow fonder, and boy, have we missed all of you! We’ve been cooking up something big and it just didn’t seem right to give you little teasers when our end goal was just within finger’s reach. We’ve been collecting more materials from Home Depot and cutting more tiny little foam pieces. We’ve been working separately and together; trying to accommodate each other’s evenings all the while making progress. We’re really proud to give you this picture.

Subject Delta and Eleanor Lamb's Helmets

But fear not! We’re not going to stop at simply showing you a picture. No! We’ll fill you in on exactly how we got here. Wouldn’t want you to miss out on all the fun!

If you’ll think back two weeks ago, we’d left Eleanor Lamb‘s helmet at the papier-mâché phase. The helmet and the harness were each connected to their own wooden circle base but before we could join them, we needed to divide and conquer. With a horror movie remake marathon on TV, Daniel and I settled in for a work filled Saturday night.

Daniel works on Helmet Sara Works on Harness

First things first; the porthole. We bought a closet flange spacer ring for the actual porthole and a sealing ring to use for the inner ring but, when we set everything out, we found that it would be easier to use the ring as a stencil and cut the whole thing out of craft foam.

Porthole with Ring Stencil Porthole Center Cutout

Then it was just a matter of hot gluing the foam into the spacer ring and we had our completed port-hole. As Daniel traced the shape of the porthole onto the papier-mâché sphere I asked him if he was having flashbacks to the last helmet he punctured and he said that it’s easier the second time. And sure enough it was. He didn’t even ask me to mute the TV as he worked. What a steady hand one helmet’s worth of confidence can give you!

Porthole over Cut Eleanor Lamb's Helmet

Now to screw the porthole into the actual helmet. Our first attempt was off. Seems we need different lengths of screws to get a flat item onto the surface of a round item; duh! Luckily we had a few longer screws left over from the handles that wound up on the back of Subject Delta’s helmet. Just a few screws and we had ourselves a lovely looking porthole for Eleanor Lamb’s helmet.

Eleanor Lamb's Helmet with PortholeYou’ll notice the little black knob up Daniel’s left arm, his left, your right. That is a bit of flexible PVC pipe coupling we found at Home Depot. If you’ll check out the reference photo again you’ll notice what looks like a knob on the top of her helmet and the coupling was already close to the shape we needed. We trimmed some off the top and bottom, paired it with another PVC ring and we were just about ready to put it on the helmet.

PVC Coupling Pre-Cutting PVC Coupling pieces

PVC Pipes on Helmet

Daniel drilled yet another hole into the helmet, just big enough for the bottom piece of PVC. Then we sealed the top and bottom with hot glue. Next, we added a bottom layer of foam and we were ready for the fun part; the ribbed tubing that runs around the front and top port-holes. We used some flex tubing and, after a fun little game of tug-o-war, it was ready to stretch out and loop over the helmet. Daniel secured it with heaps of hot glue and this is what we ended up with; a handy-dandy way to cover up those pesky screws.

Tubing Around the Porthole

Believe or not; that’s only Daniel’s part of the work from that Saturday night! There’s much more to come! See you next time — TCG

Oh. Did I mention that C2E2 tickets go on sale this week? Color me excited!

Level 1-4: Final Save Point — Continue?

6 Aug

Camera - on helmet

Good news everyone; we got our supplies! We were waiting on pins and needles for the 5 mm thick craft foam to arrive so that we could begin work on the porthole. While the prospect of making sudden progress was exciting, we were both dreading the moment when we would cut the Subject Delta’s helmet and either make it or break it, so to speak.

In keeping with our practice of making prototypes before gluing or cutting, we set out to make a prototype of the porthole. For our first attempt, I did a free-handed sketch using grid on construction paper.

porthole hand drawnWhile Daniel was mightily impressed by my free-hand ovals, they weren’t as perfect as we wanted them to be. But they did not go to waste; no! We used them to figure out the rough dimensions that we needed and then plugged into Microsoft Paint. porthole computer

Much more exact, don’t you think? Based on these two templates, we cut our port-hole out of the 5 mm craft foam we had ordered from Hobby Lobby. It was surprisingly easy to cut through with the X-acto knife. However, we found that we needed to cut the entire shape out in one fell swoop rather than starting and stopping in order to adjust the foam; that’s a good way to get frayed edges buddy! I also wouldn’t recommend using scissors, you’ll wind up with lots of scraggly edges with this thicker foam.

Once we had the ovals cut from the foam, we needed to find a way to attach the bars that run across Subject Delta’s porthole. Daniel cut the dowel rods into the sizes we needed with his handy-dandy mini hacksaw and we laid it all out . We even added the rivets so we could begin to imagine it all together; also, we wanted to see if we’d left enough space for them.

porthole 1st try with back

The next hurdle was this; how do we hide the dowel rods? Do we cut them off so that they will sit, nestled nicely inside our foam ovals? No. We sandwich them in between. I’ll let Daniel tell you how we solved this problem with a little creativity and resourcefulness.  — Sara

We practiced with cutting small divots into the 5 mm foam with the X-acto knife, but it wasn’t quite as easy as cutting into the Styrofoam; or as snowy. It was impossible in fact, to get the shape we wanted without tearing it up. So we had the great idea of melting it. What I really wish we had for the job was a wood burning tool, but alas, all we owned was a low-grade hot glue gun. We tried it out, using the heated metal tip. It melted the foam somewhat but not as adequately as I had hope. So I used the only other long, flat, metal device we had. Kids, don’t try this at home. I used the gas stove and a shish kabob skewer to MacGyver myself a melting tool. I turned the stove element on high, held the skewer over the flames until it got hot, but not too hot, and slowly pressed it into the foam until I created the desired divots in both sides of the two porthole pieces. Although the melting foam did not produce a large amount of smoke, it did produce fumes, so make sure you do this in a ventilated area; I just turned on fan over the stove in the kitchen. When I finished I had the perfect slots to insert the dowels into so that we could glue the two pieces together, sandwiching the dowel rods in between. — Daniel

porthole melted eva porthole with dowel

Once we had ironed the kinks out, the moment of truth had arrived. We had to cut the porthole. Tension was high, I kept shaking out my hands and Daniel kept taking these anxious deep breaths and swooshing it all out of his lungs. We spent a long time taping cut outs of our porthole and the lights; we wanted to make sure that we compensated for the shape of the helmet with the placement and scale of our accessories. We finally settled on a placement and Daniel took our papier-mâché baby into his lap with X-acto knife in hand. I sat back. The room was silent and the air was thick with nerves and the taste of fear. I picked up my book to distract myself. Daniel put the tip of the knife to the helmet and his fingers tightened, “You’re not going to watch and support me?” he asked looking up at me. I knew that he was just stalling.

“I don’t want to distract you,” I said. “And I’m so nervous!” He took another deep breath and his eyes focused on the helmet. I raised my book, pretending not to watch. He took a final shallow breath and held it as he applied pressure and the X-acto knife popped through the paper mache. He finally exhaled. It was done. — Sara

helmet cutting

The first cut had been made. There was no turning back now. I began cutting into the helmet following the line we had traced with our template. I cut slowly and methodically, in short sawing strokes so as not to tear or bend anything. Things were going smoothly until I hit the first of the underlying skeletal crossbars. I stopped and threw a quick, concerned glance at Sara who looked up from her book only briefly with a look of ‘you got this, but don’t expect me to help.’ I continued on for what seemed like a full hour and then I was back around to where I started. I made a couple of final saws and then the section ‘popped’ out of the helmet with a soft crack and there was now a big, gaping hole in our hard-earned masterpiece. — Daniel

Did all of our forward planning pay off? Would all of our blood, sweat and tears be paid back in full? Or will Sara have to strangle Daniel with a pliable piece of cardboard from the helmets frame because they have to start all over again?

Tune in next week for the Bioshocking conclusion to: The Cutting of the Subject Delta’s Helmet