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Picture of Champagne Cork Darth Vader
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This legendary Star Wars character has been on my Corky To-Do list since the beginning, but I never had time to make it until now. This 7cm Darth Vader Corky has probably been the most diverse (and possibly most challenging) Corky yet. Here's how I did it.
 
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Step 1: Supplies

Above are some photos of some of the supplies I used. I was planning on gathering everything I used and taking a picture of everything at once when I was done, but there were so many different things I gave up trying to find them all again. Even though I used a lot of different supplies, most of them are simple things that most people will have in their home, so they shouldn't be too hard to find. 

Tools
  • UHU glue
  • Scissors
  • Black, silver, blue, and red permanent markers
  • Craft knife
  • Glossy varnish
  • Soldering iron and solder
  • Third hand
  • Pliers
  • Hot glue
  • Wood glue
  • Super glue
  • Clamps             
  • Dough roller
  • File
  • Sandpaper
Materials:
  • Champagne cork
  • 3mm red LED
  • Mini slide switch
  • Insulated wire
  • Button cells (I got them from a 12V battery, but you can buy them separately as well)
  • Small battery spring
  • Transparent plastic stirring rod
  • Thick aluminium foil (I got it from a disposable aluminium food tray)
  • Black sculpey
  • Pieces of black fabric
  • Cardboard
  • Black rubber (from bicycle tubing)
  • Black foam rubber
  • Grey card
  • Aluminium tape
  • Small pins
  • Paper

Step 2: The Innards (LED)

Chop your champagne cork in half with a saw, bread knife, or craft knife, and carve out the inside as shown above. Make sure that the switch, LED, and button cells fit. 
Then, solder the positive leg of the LED to the small battery spring, and the negative leg to the switch. Solder the other leg of the switch to the negative battery plate, and glue the two battery holding parts to the inside of the cork. Make the wires as short as possible, so that all the parts will fit inside the cork when you close it.
Fill all the empty space (except for the battery compartment) with hot glue, so that the switch stays in place and there won't be any accidental short circuits once the cork is closed.
Use wood glue to glue together the two halves, clamping the cork to let it dry.

Step 3: Mask

The mask was surprisingly difficult to make. But whenever I thought that I wasn't going to finish, I thought of Vader's quote, "I find your lack of faith disturbing".
Even though it turned out alright, please DON'T DO IT LIKE THIS. I modeled the mask around a cork, and as I baked the Sculpey the cork expanded, causing everything to crack up. So whatever you do, don't bake the mask on the cork itself.
If you want to follow my example anyways, the photos above describe my process.

Step 4: Helmet

To stop the helmet from sticking to the mask, bake the two parts seperately (I had to cut some parts of the mask out of the helmet).
The time and temperature at which to bake the Sculpey depends on the brand and type, so check the packaging.

Step 5: Battery Lid

Picture of Battery Lid
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The lid is fairly simple to make. Just make sure that the cardboard circle and the cork align.

Step 6: Clothes

Picture of Clothes
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Cut a strip of black fabric and glue it around the cork with UHU glue, joining it at the side where the LED is. Don't forget to leave a hole for the switch at the back.

Step 7: Belt, Shoulder Pads, and Panel

Picture of Belt, Shoulder Pads, and Panel
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Step 8: Cloak

Picture of Cloak
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Cut a piece of black fabric large enough to cover the whole of the back side of the cork so that it flows like a cloak.
Leave a whole for the button at the back. Whereas I always used glue to attach the cloaks in previous Corkies, I realized that small pins are much easier and don't make the cloak as stiff.

Step 9: Details

Picture of Details
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I showed and described some of these details in some of the other steps, but here they are again. 

Step 10: Lightsaber

Unfortunately I forgot my camera when I sanded and cut the rod into the lightsaber blade, but it really depends on your rod, so the instructions would probably have been useless to you anyways. 

Step 11: Done

And that's how I made it. If you decide to make your own, I'd love to see a picture of it, which you can post below. 

May the force be with you.
sjroth (author)  Darren Krieger1 year ago
The champagne corks? I call them Corkies.
I think hot glue would work, but it might be hard to get the sticks to the right shape because they're so soft.
J-Five1 year ago
Use the "cork" Luke!!!
Come to the dark side... We have champagne!
danilo.bar12 years ago
Really well done! I love it!
The only flaw is given by the fingerprints left on the modeling clay.
I recommend the use of oil (also simple cooking oil) to smooth surfaces, when you are modeling the pieces.
sjroth (author)  danilo.bar12 years ago
Alright, thanks for the tip. I'll keep that in mind the next time I use Sculpey.
I was going to suggest the same thing, I did that to my Mr. Spock and several other sculpey things I've made. It will work with any oven bake clay. Baby oil also works well. :)
g00dhum0r2 years ago
This is awesome and creative. Would make a great present for a star wars fan. Shows you put in time and effort ;)
Funniest thing ever!! So Creative, LOVE IT!!
PeckLauros2 years ago
Perfect!
AmyCat592 years ago
I feel a very small disturbance in the Force... it sounds a little like giggling... :-)
lbrewer422 years ago
"Impressive, most impressive."
sjroth (author)  lbrewer422 years ago
Hahaha, thanks
Joyceline2 years ago
Awesome!! Loooove it!!! BUT...Can you change the batteries???
sjroth (author)  Joyceline2 years ago
Yeah, of course. The cardboard and cork lid (step 5) is only pressed in -- it isn't attached. You can easily remove it with a screwdriver or something. The spring inside also allows the batteries to be removed and replaced easily.
seamster2 years ago
ha ha! This is great. Well done. I love Darth Vader-themed instructables.
suttonabc2 years ago
This is SO cute! I'd love to see ANY more little characters you make. :) (Especially a little Yoda, I would.) :)
canida2 years ago
This is SO CUTE. The glowing lightsaber is perfect.

Maybe use a no-bake alternative to sculpey for corks? Sugru cures overnight and keeps a nice elasticity.
sjroth (author)  canida2 years ago
Thanks, I'm glad you like it.

That would probably have been a better option. I should order some Sugru for future projects.
Producracy2 years ago
Looks great and would be a good DIY project for others.
How long did it take to make?
Thanks, -Andrew, producracy.com
sjroth (author)  Producracy2 years ago
Around five hours, with all the trial and error. If I remade it, it would probably take me around three.
ben77982 years ago
awesome job! you should make yoda next
sjroth (author)  ben77982 years ago
Thinking about that too, I was.
yes! it's finally here!
Misac-kun2 years ago
Amazing!
Honestly to me it looks more like when Stewie was playing Darth Vader lol.
eeeeeeeeee! Look at his little lightsaber! This is absolutely adorable.