Instructables
Picture of Giant Lego Darth Vader
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This is a 22-inch tall Lego Darth Vader toy I made for my kids. 

He is pose-able and all of the individual body pieces come apart just like a real Lego minifigure.
 
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Step 1: Planning

Picture of Planning
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My goal was to make a  lightweight Lego man that was about 2 feet tall, and end up with a finalized pattern that I could use to create more giant Lego men in the future. 

This Lego Darth Vader is made primarily from foam core, which I purchased from a picture framing shop. You can find foam core at Walmart as well as most office supply stores. I also used some brown craft paper and thin painter's masking paper, both of which I got at my local hardware store. I also used some flat single-ply cardboard, craft foam, and some other basic materials. 

I based all my dimensions off of the second image shown here, which I found through a google search. I enlarged it to fit an 8.5" by 11" paper, and printed it out. From this sheet, I measured and multiplied each length, diameter, etc., by 3.5 and and drew out all the pattern pieces accordingly. (It's projects like this that make me love the metric system. Millimeters are awesome.)

I apologize that I am not including some kind of pattern for this, although I may do so in some later project. I made approximately 80 individual pattern pieces which were then used to produce the over 300 individual pieces that went together to make this Lego man. (And that doesn't include any of the trial pieces and re-do's.) So it'll be a lot of work to turn those into a PDF anytime soon!

Overall this may look quite daunting and complex, but each individual step was actually quite simple. The problem was that there were just a whole lot of steps, and lots and lots of repetition for certain pieces (like the head and the helmet). I worked on this a little at a time over the course of a month, and eventually it was done. I enjoy the creative process, and find projects like this to be very therapeutic.

To make this, there were some tools I just couldn't do without. Aside from basics like white glue, hot glue, and scissors, I used a utility knife with a snap-style extendable blade, a compass, a protractor (a round 360-degree version), a metric ruler, and an exacto blade with lots of extra blades.
krummrey16 days ago

WOW! That looks great.
Have you seen the Minifigs from Ninjatoes? I've built Luke Skywalker.
Let's have a fight and see who wins ;)

https://ninjatoes.wordpress.com/2013/01/20/lego-71..

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seamster (author)  krummrey16 days ago

That's cool! I hadn't seen those. Some papercraft stuff is just amazing!

bobes360 made it!23 days ago

Hi after about a month of occasional making it I finally made it! But I did not follow your instructable so I made my own. If you have time please check it out : http://www.instructables.com/id/Making-BIG-lego-Darth-Vader/

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seamster (author)  bobes36022 days ago

You did great! I'm glad to see you pushed through and figured it all out. As you practice and continue making things you'll only get better and better. You only need a little talent and a lot of determination to make awesome things; you've obviously got enough of both! Good work, keep it up!

Awesome
JackDF1 year ago
wow
Just amazing!
GpaSteve1 year ago
This is great, my grandkids would love something like this. May have to add something like this to my 'to do list'.
Oh, my it appears I answered my own question! I need to brush up on my art skills and see if I can created this wonderful instructable.
seamster (author)  EducationSmellsSweet1 year ago
I see you found it! It's quite a project, but if you have a lot of determination, you could pull it off. Good luck!
I am going to try it, I won't lie, I'm terrified, lol!
seamster (author)  EducationSmellsSweet1 year ago
Be afraid, be very afraid!

But also . . . be persistent! Mine was not a weekend project. I worked on it for a long time. It was worth it, but it was a LOT of work!
Alright you talked me into it, time to get out my tape measure!
hankd1 year ago
WOW! This is great! Is there a pdf that we can print out and do this at home? That would be totally sweet!
seamster (author)  hankd1 year ago
Hi, thanks! Glad you like this. I really tried to put together a plan for this, but there were just too many variables involved to actually create a plan that would be usable. It started to really slow me down on the project (trying to make usable plans along the way), so I scrapped the idea. ...Bummer, I know!
poofrabbit2 years ago
Holy cow batman I want one!!!
monsterlego2 years ago
Awesome! **5**
benjib0t2 years ago
Congrats! This is an awesome project and a great instructable.
seamster (author)  benjib0t2 years ago
Thank you, and right back atcha!

A homemade settlers game has been on my radar for a while, but I'm still on the fence as to what style I want to make. Yours was especially well done. Congrats on your win!
I wanted to say congrats on the big win!
look forward to seeing more from you.
Grasshopper1221
seamster (author)  Grasshopper12212 years ago
Thank you very much!
P.S hope you win ;)
YOUR PROJECT ROCKS!!!!!!!!
sunshiine2 years ago
This is totally awesome and worth voting for. Is this for the toy contest? I wish you the best!
sunshiine
This is prime example of instructables finest.
And a perfect contest entry for the toy challenge.
I would like to let you know that i voted for your entry.

It pleases me to see an in depth instructable, and not one that only has 3 or 4 vague steps.
seamster (author)  TimTheScarecrow2 years ago
I appreciate your kind words, thank you!
Z0M8I32 years ago
This is GREAT! please let me know if you end up making a pdf, I would LOVE to make a few lego guys for my daughters room. Although I have to admit, with the wonderful detail pictures I can just about build one right now if I just had the foamcore.

Great Job!
mikeasaurus2 years ago
When your kids remove the helmet, you should to gasp "Luuuke, let me look on you with my own eyes" (then collapse dramatically). Or maybe just reenact the Cloud City battle scene.