During school last year, i was offered a welding course as an extra and i learnt how to weld, i decided to try and weld a Hau but i didn't know what exactly to do. I used CrunchbiteNuva's papercraft design, first actually making the mask in paper to see how the pieces connected. I then adhered the paper pieces to sheet metal, which isn't easy to weld so a spot welder was used. The pro of that was accuracy at the cost of looking a bit burnt. This design will be a prototype as I am going to modify the pieces so that the mask will be easier to weld and be welded another type of welder as the spot welder is quite tedious and doesn't result in continuous and strong welds.
Tahu Hau for scale
The next mask will be easier to build but do note that the hau is considered a difficult mask to design, a Kanohi Miru or Kakama would be easier to build and would require little to no modification, depending on the welder. I'm not sure when the next mask will be built as i don't have access to any tools currently having just moved house.
Tools: spot welder, tin snips, file, assorted hammers, pliers and adherent