Here is a little tutorial that can be applied to many different costume props using pepakura and paper mache. It's fun, easy and inexpensive! This is the method I used to create an "adamantium" jaw for my husband's Deathwing costume. Use this tutorial to create your own or apply it to other projects! Happy crafting!
For information on using Pepakura, watch this helpful video [link]
For an overview of the whole costume, click [link]