Introduction: Homemade Darth Vader Melted Mask

In this dark side instructable, I'll show you how I turned a toy plastic Vader mask into an awesome Star Wars prop like the one seen in The Force Awakens trailer.

I'm sure we've all seen the Darth Vader melted/damage mask from the upcoming movie trailer!

How do I make my own melted Vader mask and what do I need?

  • Plastic Vader mask (I found a second hand one on eBay)
  • Reference image (keep to hand when working)
  • Extra plastic (I used an old container lid, same thickness)
  • Blow touch or heat gun
  • Scraper
  • Hot glue gun or 3D printer pen
  • Spray and acrylic paint
  • Respirator & eye protection

When heating plastic you need to be in a well ventilated area with respirator and eye protection. Please note that this can be dangerous if not controlled and you will need to take responsibility for your own actions. I will not be held responsible for any accidents.

To start, I recommend watching the short YouTube tutorial on making your own melted Vader mask.

Step 1: Heat & Sculpt

Picture of Heat & Sculpt

Using a blow torch or heat gun, heat a small area at a time in a controlled manner, making sure not to over heat one spot.

Once plastic is soft, dab with scraper and sculpt. Keep referring to you reference image and add material if needed. Again I recommend watching the video tutorial for a better understanding.

Step 2: Hot Glue for Detail

Picture of Hot Glue for Detail

A good way to add more material and extra detail is to use a hot glue gun or a 3D printer pen. Just draw with it.

Step 3: Painting

Picture of Painting

Once your plastic Vader mask has cooled down, give it a coat of grey primmer and black spray paint.

Using acrylic paint do some rust effect using some browns and reds. Dab with brush.

To give it a brushed metal look I did a dry brush technique using metallic silver, and to finish I used the force to mount to my wall.

There really is no wrong way to do this, effectively all your doing is turning a toy plastic mask into a mangled mess, like the one from your reference image.

I hope you found this Star Wars themed instructable inspiring?



JustusC (author)2017-09-01

Very nice workmanship!

Nreal Spark (author)2016-02-01

Looks very nice indeed !

SCHLEPIC (author)2016-01-22

I agree, I think a heat gun would have provided you much more control. Or you could have even held the torches a little farther away from the material. That being said, the mask turned out phenomenal! I really want to try this now. This would be a killer addition to a game room or man cave.

dathcha (author)2016-01-16

I saw it!

nickolaip (author)2015-12-27

*Someone cant finish the project here "I will finish what you started"

dathcha (author)2015-12-01

This is awesome!!! im so exited for the new star wars movie!

Knextremely stupid (author)2015-11-10

Can we melt it when we are wearing it?

What do you think?

fituro (author)2015-11-09


FPSXGames (author)fituro2015-11-12


MandalorianMaker (author)2015-11-09

Wow it looks awesome, I will have to try this.

Thanks, be sure to add image here once done. Have fun, be safe.

About This Instructable




Bio: I've always been a very creative person and a self confessed video gaming geek. I'm a husband, father, artist and blogger
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