Look around to see what other fans have done from card board to paper mache to fabric to foam. I have a friend who did a good look fabric costume. Pics of it on Facebook. But look around and just look and ask. There is a lot out there made out of a lot of different materials and how each one looks along with what you want to do.

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Jazz LIVES!!!

TransFormSlash: Slashy all the time!
[link]

Ask yourself: What would Starscream do?

My Blaster cosplay is cardboard AND craftfoam, if that helps at all ^^

I made alot of paper mock-ups too, especially for the helm and face before I settled on a final design.

I used a few other materials, soem vinyl plastic and seat cushion foam too. Hrm, have you thought of trying Wonderflex?? I'll say this, cardboard and craft foam, and wonderflex is light enough to walk around in, but after a while it all does start to feel heavy. Make alot of sketches and designs first too to see what works best ^^

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dare no tameni moeru no?

General Hawk: Hm, it's a communiqué from Dr. Mindbender to Zartan and his Dreadnoks.
Sgt. Slaughter: You mean, they can read?

Don't go knockin' the cardboard. It's a viable material to use. Not so much on its own, but as a one-of-several type thing.

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"Warriors of fate, you shall dance bravely,
Use your golden wings, and fly to the skies!
Heroes of steel, they do not have the word "retreat" in their minds.
Continue to command with your raging, burning souls!
To eternity! To eternity!"

I know but on the outside its a nono

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If you love transformers then join The Dream house.

what exactly is wonderflex? I doubt I'd be able to get that here in europe.. but yea..

--
If you love transformers then join The Dream house.

I know there's a website with it somewhere but I hear it kinda pricey. But you can get a 'sample' set that's not so priccey that has sheets in three sizes. But you'd need a heat gun to mold it and those, I think, run between $30-$60 over here.

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dare no tameni moeru no?

General Hawk: Hm, it's a communiqué from Dr. Mindbender to Zartan and his Dreadnoks.
Sgt. Slaughter: You mean, they can read?

@_@ that'll be too pricy for me.. expecially since it would need shipping too

--
If you love transformers then join The Dream house.

You could always try the people on the Transcostumers site for advice?

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Peace isn't the opposite of war, it's creation.

Can't promise it'll be done this week, or the next, or the week after that, for pressing matter reasons, but that 3D TC helmet foldout is something I can fix most probably.