Wearable Kanohi Kakama ( Bionicle Pohatu Mask )

UNITY, DUTY, DESTINY!

Printing Instructions

For most printers, please use the halved version of the model. The full version is meant for printers with a print volume of at least 260mm x 260mm x 260mm. If using the halved version, you can mirror the model in your slicer to get the other half of the mask.

Both versions of the model require supports to print, I used Tree/Organic supports with “On buildplate only” turned on.

The print shown in the images was done with a 0.6mm nozzle at a layer height of 0.2mm, a 0.4mm nozzle should also work for this model.

What You'll Need:

Materials:

• Upholstery foam (For padding the interior of the mask)
• 1" wide elastic strap (About 12" long)
• Black Sheer fabric (A ½ yard will be more than enough)
• Black fabric, thick enough to block light (A ½ yard will be more than enough)
• Bondo, or whatever body filler you prefer (Only if using the halved model)
• Spray paint (The original Kanohi Kakama came in more colors than just brown, go nuts)
• Clear coat spray (Use one compatible with your chosen brand of spray paint)

Tools:

• Hot glue gun and glue sticks (Do not use high-temp glue sticks with PLA)
• Various grits of sandpaper (I used 80, 120, 220 and 400)
• Utility knife for cutting foam
• A Sewing needle and some thread (Preferably the same color as the elastic straps)
• Whatever glue works best on the plastic you print with (Only if using the halved model)

Optional:

• Black plasti-dip spray, or other brand of liquid rubber (for coating the foam padding)
• Sewing pins (Will make your life easier when fitting the strap)

Build Instructions

1. Sand down the outside surfaces of the print(s)
   1. Start with the lowest grit sandpaper you have
   2. Sand until the layer lines are sufficiently smoothed
   3. Move onto the next grit of sandpaper
   4. Sand until you remove the scratches from the previous grit
   5. Repeat 3 & 4 until you run out of grits of sandpaper
2. Clean the print(s) to remove any dust and debris
3. If using the halved model…
   1. Glue the two halves of the mask together
   2. Fill the seams with the body filler
   3. Sand the body filler until it is smooth with the rest of the print
   4. Clean the prints to remove any dust and debris again
4. Paint the model, clear coat it, and let everything dry. Follow the instructions for your specific paint/clear coat.
5. See the attached image below to help with steps 6, 7, & 8
6. Add the fabric to the interior of the mask
   1. Cut out pieces of the sheer fabric to fully cover the two eye holes (make sure to cut the pieces slightly larger than you need to make positioning/gluing easier)
   2. Cut out pieces of the thicker fabric to fully cover the three vent holes (make them slightly bigger just like the sheer fabric)
   3. Use hot glue to attach the fabric pieces to their respective locations'
7. Add the foam padding
   1. Cut down three pieces of foam to fit in the three green spots shown in the below diagram
   2. Try to hold the foam pieces in place by hand and double-check the mask fits on your face before proceeding
   3. Feel free to modify/add more padding if you feel the padding does not fit right
   4. (Optional) Coat your foam pieces in plasti-dip/liquid rubber. This helps reduce light reflection from inside the mask.
   5. Use hot glue to affix your foam pieces in place
8. Attach the strap to the mask
   1. Cut the strap down to slightly longer than you need
   2. Put one end of the strap through one of the mounting holes, and fold it over
   3. Sew along the fold to fix it in place (nothing fancy needed, any basic stitch will do)
   4. Put the other end of the strap through the other mounting hole, and fold it over (make sure the strap isn't twisted!)
   5. Use a pin or your sewing needle to temporarily hold the new fold in place, don't stitch it together yet.
   6. Be careful not to poke yourself during the next step
   7. Try the mask on to check how well it fits. If it feels too tight or too loose, remove the pin and adjust the strap accordingly.
   8. Sew the fold in place like previously