I think DJForce might have had some influence on this project with his awesome Grayskull turret. I got a nice clean sample of the original cutout on Ebay for $15, scanned it into Photoshop and cleaned it up a bit. The file size ended up being around 40mb but the print came out beautifully! Emailed the file, and about two weeks later got it FedEx. You can still see some rubbing on the cardboard around the edges from the original scan, but it actually looks very cool like that! Total project cost me about $115, which I have to say is not too shabby at all for a 6 foot Grayskull Robot!!! After getting him, I kinda wish I had made him 7 foot, but he is awesome nonetheless. I'm hoping to bring him to Power Con next year if I get a booth again. I was thinking it would be really cool to cut out the face area and have people pose and take pictures. Not sure if I will do that or not, but its a thought.
The He-ManCave is still under construction, so please pardon the mess.