Fasnacht in Helvetia: Fallout 76, Mask Making, and One Very Cold Night

Introduction

Welcome to a tale woven with adventure, creativity, and a touch of West Virginian charm. Our journey began in the digital landscapes of Fallout 76, where the post-apocalyptic wilderness of West Virginia unfolded before us in stunning detail. Hours turned into days as my dad and I roamed the virtual wastelands, discovering hidden treasures, battling West Virginia monsters like the Mothman and the Grafton Monster, and uncovering the remnants of a world long gone.

It was during those adventures that we stumbled across the Fasnacht event in Helvetia, West Virginia. Fallout 76 recreated the event with colorful masks, music, robots marching through town, and references to local traditions we had somehow never heard of before despite living in West Virginia ourselves. Seeing this tiny mountain town and its traditions immortalized inside a Fallout game instantly made us want to experience it in real life. Before long, we decided that if we were going to Fasnacht, we needed masks of our own.


Discovering Fasnacht in Fallout 76

Our introduction to Fasnacht in Fallout 76 felt like uncovering a hidden gem buried deep inside the game world. Fallout has always been great at environmental storytelling, but seeing actual West Virginia traditions represented in a major game felt different. It felt personal. The game captured Helvetia as this strange, charming little town full of folklore, old traditions, music, bonfires, and bizarre masks.

The more we looked into the real event, the more fascinated we became.

Fasnacht, derived from the German word “Fastnacht,” is a traditional pre-Lenten celebration brought to Helvetia by Swiss immigrants in the late 1800s. The event is centered around driving away Old Man Winter and welcoming spring. In Helvetia, the celebration includes handmade masks, music, food, dancing, and a nighttime parade through the town ending with the burning of Old Man Winter himself.

Helvetia is tiny, tucked away in the mountains of West Virginia, but during Fasnacht it transforms completely. People travel from all over just to experience the celebration. Fallout 76 introduced us to a piece of Appalachian culture we otherwise may never have discovered, and once we learned more about it, we knew we had to go.

Of course, we also knew we couldn’t show up empty handed.


Creating the Monster Man Mask

For our first Fasnacht, I decided to create a mask inspired by the Monster Man mask from Fallout 76, one of my favorite mask designs in the game.

The build started with a giant balloon that became the base of the head. Once I had the rough size and shape I wanted, I started layering paper mache over the balloon to create the shell of the mask. Paper mache is messy, time consuming, and takes forever to dry, but it’s also surprisingly durable once enough layers are built up.

After the base hardened, I started working on the facial features. The nose was created using tinfoil wrapped around a manipulated wire hanger that I bent into shape by hand. Once I liked the shape, I paper mached over the entire thing and attached it to the head.

The eyes were formed using tinfoil underneath layers of paper mache, while the lips were built up using thicker paper mache to create more dimension around the mouth area. The teeth were cut individually from poster board and glued into place one at a time. At this point the mask looked absolutely insane sitting on my desk, but slowly it started becoming recognizable.

Once the structure was complete, it was finally time for paint.

I painted the mask before starting what was probably the most tedious part of the entire project: the hair. The hair was made entirely from folded strips of red cardstock glued individually onto the mask. Over. And over. And over again. It felt like it took forever.

Finally, I cut out eye holes… sort of.

That decision would come back to haunt me later.


Fasnacht Night: Cold, Dark, and Barely Visible

The night of Fasnacht finally arrived, and honestly, it was incredible.

We explored the town, grabbed some Helvetia souvenirs, walked around looking at everyone’s costumes and masks, and soaked in the atmosphere. There’s something surreal about seeing this tiny mountain town completely transformed by music, bonfires, masks, and hundreds of people celebrating together in freezing temperatures.

And it was freezing.

Not “a little chilly” freezing. My toes legitimately felt like ice cubes by the end of the night. The cold settled into everything. On top of that, it was much darker than I expected. Once the parade started moving, visibility inside my mask became a real issue.

By “real issue,” I mean I could pretty much only see out of one eye hole.

Most of the parade was me grabbing onto whoever was closest and blindly walking forward while occasionally catching glimpses of the festivities whenever somebody nearby had a lantern or flashlight bright enough to light things up. It felt like navigating through darkness using random flashes of vision every few seconds.

As ridiculous as it sounds now, it actually made the experience kind of hilarious and memorable.

That first year taught us a lot:

  1. Visibility matters way more than you think.
  2. Start building masks earlier.
  3. Wear at least two pairs of socks.

Year Two: Learning From Our Mistakes

For our second Fasnacht trip, we went in much more prepared.

We gave ourselves more time to work on the masks instead of procrastinating until the last minute. We also knew visibility had to become a top priority. And most importantly, we knew exactly how cold it was going to be this time around.

This year I decided to create a Deathclaw mask.


Choosing the Deathclaw

I selected the Deathclaw as my mask’s theme due to its menacing yet iconic design and my long-time fascination with the Fallout series. The creature’s formidable presence in the game made it one of those enemies you never forget encountering for the first time. If you accidentally stumbled into a Deathclaw area too early in the game, you were probably about to have a very bad time.

I wanted my mask to capture that same feeling.

The Deathclaw also gave me opportunities to improve on things I struggled with during year one. The design naturally allowed for better visibility by placing my face inside the creature’s mouth instead of behind tiny eye holes. It also let me experiment with larger structural elements like horns and more complicated shapes.


Building the Deathclaw Mask

Knowing visibility was important this time, I started with a wearable face mask as the foundation of the build. This served multiple purposes. First, it hid my face inside the black interior of the creature’s mouth. Second, it gave me something secure to strap directly onto my head using Velcro. And finally, it helped distribute at least some of the mask’s weight.

The large horns on the sides of the Deathclaw’s head were made from wire and tinfoil, a trick I learned from year one. Once I had the rough shape I wanted, I layered paper mache over them using cheap paper towels, which actually created a pretty interesting texture naturally.

The teeth were made using a moldable thermoplastic that comes as little plastic pellets. You heat water, pour the pellets in, and they become soft and moldable. Once removed from the water they harden surprisingly quickly, but there was still enough working time to shape each tooth individually before they cooled.

I also used this same material for the eyes, although honestly, looking back, golf balls probably would have worked just fine and saved me some effort.

The mouth structure itself was mostly wire and tinfoil, while the top of the head used cardboard covered in paper mache. One major thing I learned during this process is that paper mache absolutely hates sticking to wire and foil by themselves. You really need some kind of solid base material underneath or you end up compensating by adding way more layers than necessary.

It worked in the end, but there were definitely moments where I realized I probably should have used cardboard much more heavily throughout the structure.

The horns and teeth were attached using hot glue before being blended into the rest of the mask with more paper mache. Slowly, the Deathclaw started looking less like random craft supplies glued together and more like an actual creature.


Painting and Finishing Details

Once construction was finished, it was time for paint.

I used a combination of spray paints and acrylic paints to create the Deathclaw’s skin tones and details. The mouth area got a glossy finish to make it look wet and more organic, while darker washes added depth to the cracks and textures throughout the face.

One of my favorite finishing details was adding fake saliva around the teeth using hot glue. It sounds ridiculous, but once stretched and layered carefully, the glue actually created a surprisingly gross and realistic effect.

As I put the finishing touches on the Deathclaw mask, I realized procrastination had once again gotten the best of me, and the mask didn’t quite sit how I originally imagined. Still, it worked far better than my first mask, especially when it came to visibility. It definitely wasn’t perfect though. There was a lot of weight sitting on my head and it wasn’t distributed very well, but for a few hours at Fasnacht it would absolutely do the trick.


The Moon Man Mask

Meanwhile, my dad embarked on creating the Moon Man mask inspired by Fallout 76 and the classic 1902 black and white film A Trip to the Moon by Georges Méliès. The film famously features astronomers launching a missile into the moon’s eye, creating one of the most iconic images in film history. Fallout references this imagery heavily with its version of the Moon Man.

His process was similar to my first year’s mask build. He started with a balloon base layered in paper mache before adding clay details to create the moon’s craters and texture. The missile itself was made from a pool noodle, which honestly worked surprisingly well once painted and integrated into the mask.

The final result looked both creepy and weirdly charming in the best possible way.


Fasnacht Year Two

The second year felt completely different from the first.

Not only were we more prepared, but there were dramatically more Fallout fans this time around. During our first trip we only saw a handful of people referencing the game. This year, Fallout masks and costumes were everywhere. Everywhere you looked there were masks we recognized from the game wandering through Helvetia alongside traditional Fasnacht costumes.

It genuinely felt like Fallout 76 had introduced an entirely new generation of people to the celebration.

The parade itself was also far more enjoyable this year simply because I could actually see what was happening. Instead of blindly stumbling through darkness holding onto strangers for guidance, I could finally take in the atmosphere properly. The parade wound through town surrounded by music, lights, costumes, and bonfires before eventually ending near a massive fire where everyone gathered together against the freezing cold.

The combination of local tradition, gaming culture, creativity, and community created an atmosphere that’s honestly hard to describe unless you experience it yourself.


Conclusion

What started as a Fallout 76 curiosity turned into one of the most memorable traditions my family has experienced together.

Fasnacht became more than just a parade or a road trip. It became a creative challenge, a reason to build things with our hands, and a way to connect gaming with real-world history and culture. From stumbling blindly through the freezing dark in year one to improving our masks and seeing Helvetia filled with Fallout fans in year two, every part of the experience felt unique and unforgettable.

And honestly, that’s part of what makes Fasnacht special.

It’s weird.
It’s creative.
It’s cold.
It’s chaotic.

And we’ll absolutely be back again.

Crafting a 3D Printed T-800 Terminator: A Journey into Robotics

Introduction

Ever since I got into 3D printing, I always wanted to tackle a project that felt bigger than just another print off the build plate. I wanted something that looked like it came straight out of a movie workshop. That project ended up being a full T-800 Terminator inspired by the classic Terminator films. What started as “this would be cool to print” quickly turned into a crash course in electronics, painting, servos, wiring, troubleshooting, and learning how to fix problems I definitely did not know how to solve when I started.

While I had been 3D printing for a while before this project, I knew virtually nothing about Arduinos or servos going into it. That part of the build pushed me way outside my comfort zone, but honestly, that ended up being one of the most rewarding parts of the whole process.


The Beginning

The project started when I found an incredibly detailed T-800 model created by another artist online. Once I had the files, the first challenge was getting everything prepared inside slicing software for printing. That meant figuring out print orientation, supports, infill settings, and splitting larger pieces into printable sections.

At this point I already had a decent amount of experience with 3D printing, but large multipart projects are a completely different beast. Every setting matters because one bad print can mean wasting a huge amount of filament and a ton of time. Some of these pieces took ages to print, so there was always that nervous feeling of hoping you didn’t wake up to spaghetti filament all over the printer.


Trading for a Printer and Fighting the Extruder

Around the time I started the project, I had recently moved across the country and left my Ender 3 Max behind. Suddenly I went from having a printer I trusted to not having one at all. Eventually I ended up trading an old VR system for an Ender 3 Pro, which honestly sounded like a great deal at first… until I realized the printer had some issues.

One of the biggest problems was the extruder chewing through filament instead of feeding it correctly. Prints would fail randomly, filament would grind down, and sometimes the printer would just stop pushing material altogether. After a lot of troubleshooting, I upgraded to a dual gear extruder setup which finally solved the issue.

Once the printer was behaving consistently, the real marathon began: printing every individual part of the T-800. This wasn’t one single print. It was dozens of pieces, all requiring cleanup, fitting, and assembly later on. Some prints came out beautifully while others needed to be reprinted entirely. It became a long cycle of print, test, adjust, and repeat.


Sanding, Filler, and Endless Dust

After the printing phase, the project shifted into post-processing, which honestly took just as long as the printing itself.

Every piece started with an initial sanding to knock down the layer lines. After that I used a filler primer to help smooth everything out further. Then it was back to sanding. Then more filler primer. Then more sanding. Over and over until the surface finally started looking like metal instead of melted plastic.

This part of the process tested my patience more than anything else. It’s easy to underestimate how much work it takes to make a 3D print look smooth and realistic, especially for something as recognizable as a Terminator endoskeleton. The finish needed to look clean because every imperfection would stand out once paint was applied.

Once I was finally happy with the surface quality, I moved on to painting. I started with a high gloss black spray paint and worked carefully to get a smooth, reflective finish. The glossier the black base, the better the final metallic effect would look later.

After the paint dried and had that almost mirror-like shine, I started applying graphite powder. This was one of the coolest parts of the project because the transformation was immediate. Rubbing graphite into the glossy black surface suddenly made the pieces look like actual metal instead of painted plastic. It gave the T-800 that classic chrome-like metallic appearance straight out of the films.

Watching the plastic parts slowly start looking like a real robotic endoskeleton was one of those moments where the entire project suddenly felt real.


Diving into Electronics

As the physical form of the Terminator started coming together, it was time to tackle electronics.

Now to be clear, I already felt very comfortable with the printing side of the project. The electronics side? Completely different story. Arduinos, servos, wiring diagrams, coding — all of that was basically new territory for me.

Still, I knew going into the project that movement and electronics were part of what would make the T-800 actually feel alive. Static props are cool, but moving robotic components take things to another level.

So I started learning.

That meant a lot of YouTube videos, a lot of trial and error, and a lot of moments staring at wires wondering why nothing was working. But honestly, that learning process became one of my favorite parts of the build. There’s something really satisfying about slowly understanding systems that originally seemed intimidating.


Wiring Everything Together

Once I started integrating electronics into the build, the inside of the T-800 quickly became a maze of wires.

Every servo needed power and communication lines, and all of those wires had to be routed through the internal structure of the model while still allowing pieces to fit together properly. Some sections had already been glued, which meant planning wire routing ahead of time became incredibly important.

There were definitely moments where I realized I should have fed wires through certain sections before assembly, but that’s part of learning projects like this. Sometimes you figure things out after the glue has already dried.

Eventually, all the wiring converged back to the Arduino, which basically became the brain of the entire build. Soldering connections became another new skill I had to pick up during the process. Between soldering wires together, covering connections with electrical tape, and troubleshooting random issues, the electronics side slowly started making more sense.

It wasn’t pretty behind the scenes, but it worked.


Bringing the Terminator to Life

Then came the moment I had been waiting for: getting the servos moving.

And honestly? The first few attempts were disasters.

The movements were wrong, the servos jittered, some wouldn’t respond at all, and more than once I uploaded code only to have absolutely nothing happen. But after a lot of trial and error, things slowly started improving. Eventually I got the servos communicating correctly with the cheap off-brand Arduino I bought from Amazon and finally uploaded working code that brought movement to the T-800.

The first successful movements felt incredible. After all the printing, sanding, painting, wiring, and troubleshooting, seeing the Terminator actually move was surreal.

…until one of the servos broke.

Now instead of moving properly both vertically and horizontally, the T-800 mostly just nods up and down like he forgot how neck movement works. My best guess is that I accidentally got baking soda down into the servo at some point during assembly and it caused internal problems.

So the project continues.

The next step is carefully removing some super glue so I can pull the broken servo out and replace it with one that will hopefully survive a little longer this time around.


Conclusion

Creating this T-800 turned into way more than just another 3D printing project. It became a crash course in problem solving, electronics, painting, coding, and learning how to adapt when things don’t go according to plan.

There were definitely frustrating moments. Failed prints. Bad wiring. Broken servos. Endless sanding dust. But honestly, those problems are part of what makes projects like this rewarding in the end. Every issue forced me to learn something new.

Even now the project still isn’t fully “finished,” and honestly it probably never will be. Projects like this evolve over time. There’s always another improvement to make, another part to redesign, or another issue to fix.

But that’s also what makes it fun.

Seeing a pile of plastic parts slowly turn into a recognizable T-800 Terminator — and then watching it actually move — made every setback worth it.