How to make a Darth Vader costume out of cardboard boxes

Step 5 Box Vaders Head

The Face:

After googling for a few mins I came up with a simple & what I thought looked like a good enough pattern for Box Vaders face.

I took my left over silver material and cut a series of shapes.

1 large circle -

I took the circle and cut in half. Using one half of the cut circle I then cut that in half to make the helmet

With the other half of the circle, I cut  that into 2 pieces  & cut out two inserts to make eye holes.

2 triangles -
 
Cut to the same size to make cheeks

1 small circle for a nose

1 large triangle -

This one was a little more difficult. To make the mouth I folded the triangle in half and using a pen drew on the silver material to make a grate then carefully cut out the insert to make mouth.

Once you're happy with your face simply position and glue.