Chewbacca Mask Foam Templates and Hairing

This digital templates include guides for making Chewbacca Mask with EVA foam and instructions for hairing. For adults and kids! 
Always follow the foam build video and hairing video.
The templates are used to cut the 6 to 10mm thick (8mm recommended) foam to make each part of the mask.
This is an original design inspired on Star Wars movie.
The templates are in PDF files for letter or A4 paper size at 100% for adult or check the table for other head sizes. Use Adobe Reader to open the files and select the correct paper size in the print setup. If you print in A4, use in Adobe Acrobat the "Actual Size" option to print on A4 as a letter size.
Check the print scale with a ruler on the first page before printing all the pages.
Also check at the end of this text to see everything you need and more details.
You can check the final quality here, from a customer who sells the end product built using my template:
https://www.etsy.com/listing/1872719969/chewbacca-mask-realistic-cosplay 

Templates include all helmet with these parts:

FOAM:
Head
Face
Nose
Chin
Tongue
Mouth
Lip Mechanism (Optional)
Pads and Strips
Back Cover
Adding Voice (Optional)
Recommendations (read first)

HAIRING:
Templates for hair direction and length
Instructions on how to blend the hair

3D PARTS (STL format):
Dental parts with or without Lip Mechanism
Nose (can make it with foam)
Sound Adapter
Goggles of Vandor Heist
Foam build and Hairing video:
https://youtu.be/ylfiLtqelOQ

What we need for Chewbacca mask:
https://youtu.be/wgL8OZQFcg8

UPDATES, recommended:
Adjusting Face with Chin
https://youtu.be/N8owM54xO6c
Lip Mechanism & Joining Face with Chin
https://youtu.be/3CDDcE5T4Po
Mouth
https://youtu.be/vBXBTUzP2hs
Adding the mouth
https://youtu.be/JKxuvv7d6u8
Eyes Pad
https://youtu.be/mmEnjM4qcHQ
Straps
https://youtu.be/JKE1OABJ-H0
Hair direction and Length (easier and accurate)
https://youtu.be/E6_GS7MsdmY

Also I recommend do not do transition area, just jump from gray to blonde directly.

For this template, the things you will need are:
1. 3D printed denture, where we achieve a perfect bite. I provide STL files. I do not recommend doing the mask without this piece, unless you want it with the mouth fixed closed for some exhibition figure on mannequin.
2. One square meter of 8mm foam thickness for the entire mask and a marker to draw on the foam.
3. A very small piece of 5mm foam thickness for the eyes, and if you don't have you can use 3mm. Also for the nose if you want to make it with foam.
4. Half a square meter of 1mm and 2mm foam thickness for the Mouth and also for the base of the tongue. Also if you want to make your own head straps.
5. Flexible paint for foam in skin color and red color to paint the Mouth and Tongue. If you don't have flexible skin color paint, you can use white and mix it with brown, pink and red dye or paint.
6. Hot glue to fix and harden the mask from behind.
7. Flexible plastic to harden the Chin. You can use any flexible plastic, from empty paint can and cut it vertically.
8. A hole punch is also necessary to make the supports with the same plastic.
9. 3D printed Nose or you can make it with foam.
10. Fabric backpack straps and 3D printed buckle to make your own foam straps to attach the head to the mask.
11. Elastic bands to make the Lip Mechanism tensors.
12. Strong upholstery thread also for Lip Mechanism.
13. Wood and 8cm long nails. A drill to make the holes to pass the nails to make the Hackle that allows us to blend the hair (Optional, you can use a brush instead).
14. Fabric called interfacing or vlieseline to cover the triangles on the sides and for the Back Cover. Also to reinforce the head straps if you will make it your own.
15. Kanekalon hair in braids: 2 packs of number 4, 2 packs of number 44, 2 packs of number 27, 1 pack of number 8. Also brush and comb. Hairspray and hair curler are optional.
16. The basic tools: Contact cement, Paper tape, Cutters, Scissors, An element to give a circular shape with heat.

Note: recommended foam density between 60 to 80 (30kg to 50kg in kg by m3) to get the same result.

Letter pages to print: 25

Note: the templates do not include materials to build the mask and the templates will be downloaded digitally.