How to make a cardboard costume helmet

Step 7: Painting/finishing

Now coat the entire helmet with some Minwax Polycrylic sealer. This will seal everything and make your helmet much easier to paint as well as help make your helmet water resistant. Then just primer and paint your helmet! A Boba Fett helmet takes a long time to paint........

The visor is just some tinted plastic that is then glued in. I used hot glue but epoxy putty works really well too and is probably stronger. I then added some foam to the inside of the helmet to make it fit my head so it wouldn't flop around.

That's it- time to go trick or treating!

Comments

[Ernext]

this is awesome! I love it!

[Honus]

Thanks!

[AustinL97]

This is soooooo awesome...

[dylanl]

YES! YES! YES!

[vincentleest]

Are you the accordion guy?! :O

[Honus]

Nope- no accordions here!

[Under_miner]

Where did you get the tinted plastic from?

[Honus]

I used stick on car window tint from AutoZone and applied it to a clear plastic face shield from a hardware store.

[Under_miner]

Thanks so much!

[articseabear]

How do you get the paint to look damaged? Thanks

[Honus]

I just traced areas on the helmet with a pencil and then painted them in with silver paint.

[tox1cchicken]

could this be coated in fiberglass or bondo to give it a more finished look?

[Honus]

Yep- you can do that.

[hpfev]

Great tutorial!. I was just wondering what is the name of type of the foam you use and where can I get it? Thanks

[Honus]

Just use upholstery foam- it's sold at craft/fabric stores like HobbyLobby and Michael's.

[zombiesnare]

im thinking of making two: one for general wearing and one to wear when i perform my music. ill post pics when im done :D
will i have enough leftovers to do so or will i have to buy double?
thx in advance

[Honus]

You'll probably just have to buy extra paperboard.

[dnyers]

AMAZING tutorial! thanks a BUNCH for this man. I have 2 questions though. does the minwax plycrylic sealer need to be the gallon or the SPRAY? AND. can i use Fiberglass resin INSTEAD of the Minwax? if so. when do i need to put it on. i would like a nice, strong helmet =] again. thanks

[Honus]

Glad you like it! You could use polycrylic sealer in can or spray. I've always just brushed it on as then you don't have vapors to deal with. You certainly can fiberglass it- lots of people have done it. You want to fiberglass it before you do the spackling and then you want to use Bondo filler instead of spackling paste- spackling paste won't stick to the fiberglass.

[dnyers]

again, thank you for the advice. if i have any troubles ill be sure to consult you with them if thats fine?

[Honus]

Absolutely- I'm here to help!

[dnyers]

What do you prime it with? just a base coat of any color?

[Honus]

Just use a gray primer- that worked well for me.

[TxtbookNinja]

Im building a different helment but using a lot of your advice on this project. Quick question though, when using this type of cardboard should I just stick to the polycrylic sealer or can I use resin?

Only reason I ask is because Im about at that step and some other sources say resin and I honestly dont know the difference.

[Honus]

It's really up to you. Polycrylic is a lot less messy/smelly but polyester or epoxy resin will make a more durable helmet.

[lucydavi]

Here we go
http://i1086.photobucket.com/albums/j457/NarcolepticWookie/088.jpg

[Honus]

That really turned out great!

[lucydavi]

Whats up, Thanks for taking your time to make this tutorial, It has helped all of us alot. I just completed my helmet, and i had lots of fun making it. Heres a pic

http://i1086.photobucket.com/albums/j457/NarcolepticWookie/083.jpg

[Honus]

That looks awesome!

[lucydavi]

Heh thanks, The pictures not that great quality. Ill see if i can get a better one.

[adaniel5]

I know this is a lot to ask, but could someone give an in-depth explanation of the templates for the bottom section of the helmet, explaining how they fit together and what not? Looking at the PDF's I'm having a hard time understanding how everything is put together and what goes where. Any help would be much appreciated

[Honus]

No problem- give me a couple of days and I'll do an assembly drawing that shows how it all goes together as it'll probably make much more sense if I do it that way.

[adaniel5]

Thank you very much :D

[adaniel5]

Also, for the larger spots that need to be painted such as the green, red and black, would you recommend spray paint or handpainting? Because I wasn't sure considering there might be brush strokes.

[Honus]

I'm working on the drawings and should have them done soon. As for the painting I used spray cans for the large areas and then did the small details with a brush.

[adaniel5]

Cool. Also, after a number of failed attempts using different types of cardboard, I'm going to try what you suggested. Is this the right kind?

http://www.dickblick.com/products/crescent-gray-news-mounting-board/

[Honus]

Yep- that's the stuff. What I used might have been a bit thicker but that should work just fine.

[adaniel5]

My first attempt did not go well, hopefully seeing how all the templates fit together will show me what I did wrong.

[Honus]

I've updated it a bit to show how the templates go together for the lower part of the helmet so hopefully it makes a bit more sense. There's still a few other things I want to add/change but that should get you started.

[adaniel5]

Thank you very much! Especially for taking time out of your day to help me out

[Honus]

Glad to help- if you have any other questions just let me know!

[adaniel5]

Everything has been going well, I have the inner and outer glued together, and all the proper stuff cut out. At this point, I'm not sure how the cheekbone is supposed to go together and what not. Help would be appreciated. Thanks, Alex

[Honus]

Alex,
The cheekbone area is made up from three parts. First you glue the lower cheekbone part (on pages 1 and 2) to the cheekbone backplate (on page 3)- when this is done you'll have a small ledge all the way around the curve (shown on the cheekbone backplate on page 3.

The upper cheekbone (on pages 1 and 2) is glued to that ledge- this part is really tricky as you have to bend the cardboard quite a bit. The whole thing is then glued to the helmet base. I found that it helped to hold the pieces in place with tape while I was gluing them.

[adaniel5]

Sweet, thanks once again! I'll let ya know if I run into anymore roadblocks

[adaniel5]

About the lower part of the cheekbone, is it glued to the inner surface where the checkbone cut outs are, or is the inner surface cut out in that place? If so, is the upper part glued to the outer surface, and then lower glued to the upper?

[Honus]

You cut out the cheekbone area on the inner surface and outer surface and then the entire assembled cheekbone is glued in place by gluing the top part of the cheekbone to the cutout in the inner/outer surface.

Make sense?

[adaniel5]

Alright, all is good now.

[Honus]

Good deal- if you need anything else just let me know!

[A.Kahn]

Really good tutorial! I used it to build a Jango Fett helmet, and i think it turned out pretty well. So thankyou! :)

[Honus]

Great! Any pics of your Jango helmet?

[A.Kahn]

Of course! Here are 2 pics: http://img13.imageshack.us/slideshow/webplayer.php?id=photo6b48aced0e1de2dc45.jpg
I modified the rangefinder so it can be pulled down, and when its down it activates the two leds on top.

[Honus]

Wow- that looks fantastic! Well done!

[A.Kahn]

Thankyou! :)

[andymic]

I think I'll use this to make a Cyberman helmet!

[abloc]

Hi, how do you paint the worn details? thanks and srry my bad english.

[Honus]

I just draw small areas on the helmet using a pencil and then paint them using a small brush.

[riomotley]

do you know where i can find a template for a loki helmet? the helmet from the new movie?

[Honus]

Try here-
http://www.4shared.com/file/HEE20Pwu/loki_hekmet.html

That's all I found with a quick search so check it out. I'm guessing it's a Pepakura file so you'll probably need to download the free Pepakura viewer to see it. Just do a search for Pepakura.

[onehitwonder]

This is amazing! thanks for putting this up! I've had the hardest time trying to find tutorials on how to make your own armor, so this was a total relief! I found this right as I was just talking to my dad about having to buy a Boba Fett helmet from Target or something and painting it different colors. thanks a lot this really saved me!

[Honus]

Glad you like it! Let me know if you have any questions or need any help!

[Jaden Vynark]

I found basically everything at Hobby Lobby, including newspaper board. For the visor I used some dark grey thin plastic sheeting, also found at Hobby Lobby.

[ERNESTRIPIO]

YES! A DART VADER HELMET !! OR BOUSH OR SNOW TROPER OR ...

[jbvirus]

Oh man I hope you don't delete this anytime soon, i have most of the supplies and the templates together, all I am waiting for is the time to work on it. Awesome build by the way cant wait to build mine.

[Radstrike]

hey buddy, you could always just download and print the pdf of this instructable too; right under the title up there. Makes it handy and you don't have to get your computer dirty on your workspace too.

[Honus]

It'll stay here forever- you don't have to worry about it being deleted. Make sure you post pics of your helmet when it's finished!

[DarthMonkey]

hi i don't have the materials to make this so could i buy one of you just name your price!

[zombiefire]

im selling some
i'll get back to ya

[Honus]

Sorry but I don't sell them! I've got way too many other projects going and with three kids there just isn't the time...

[wraith109]

to anyone attempting this, I have found this site to be extraordinarily helpful, it has close up, high resolution, pictures, of every inch of the helmet. http://www.modelermagic.com/?p=15051

[nouserr]

great job mate :)

[dj soundwave]

i think you should show us how to make darth vaders helmet cause you're realy good on this stuff

[TBadger]

http://www.facebook.com/album.php?aid=2078392&id=65900849&l=ff8ae7248d ........ . . . .Just finished my own Build. and it came out GREAT. Ive included a link to my build album

[Honus]

That looks awesome! The hardware store lightsaber is pretty slick too. :)

[Shambles]

where might someone be able to find tinted plastic like that for the visor?

[TBadger]

I used the plastic out of a cheap poster frame from WalMart.....i tinted it with standard Vehicle tint......if the helmet is for display, just use black spray paint on the reverse side than you wnat shown and it'll be black and shiny

[Honus]

I just used a clear plastic visor shield and tinted it with auto tinting film.

[Shambles]

would they carry it at home depot? thanks!

[Honus]

Home Depot shows a face shield on their website but I don't know if they sell just the replacement clear part.

[mparent]

Just curious - how durable is the helmet? Does the strength come from mostly from the cardboard or the spackling paste? I would think that it would be a bit delicate?

[Honus]

It's actually pretty durable. I've dropped my helmet several times and it's survived quite well without any noticeable damage.

[Nathan_1]

Looks awesome, better than the retail Boba Fett helmet versions. I love the 'wear' effects especially.

[exterminator]

Thanks man

 

[saleenman101]

Sweet man is that hard to make?

[Honus]

Nope- it just takes time/patience!

[FFVIIBOY]

Too bad i dont have patience but its still really cool

[TOMNDAN]

could you do a jango fett helmet?

[Honus]

The Jango helmet has only small differences- it's essentially the same pattern without the dent.

[TOMNDAN]

I think i could do Jango Fett.

[saleenman101]

What did it take 2 hours to make?

[Honus]

No- probably more like a week's worth of evenings.

[KatanaHero]

Hey, I'm starting up an Iron Man project and was wondering if this process would work with the Pepakura files I have (that require card stock).

[Honus]

It should very well with Pepakura. Card stock might be a bit thin- a lot of people that do Pepakura with thin card stock fiberglass the patterns after assembly.

[whers boba fet gone]

this is cool and I want to make one:)thanks Honus -Boba

[anniew.tang]

Honus, I'm going to start a Jango costume soon, and was wondering if clear gloss lacquer would enhance the effect of the silver paint (make it shinier!) on the costume, or make it worse? Though I'm budgeting as well, I still would at least like to make my costume decent. What clear coating would you recommend?

[Honus]

Any clear gloss should be fine. Just remember that you can't spray lacquer over enamel paint- it will ruin it (it melts it.)

[georgetheplatypus]

how did you get the shapes to not look like brush painted on the worn metal look? every time I do a "worn metal" paint job, it always looks brush painted.

[Honus]

I just drew the "torn" shapes on with a pencil and then painted it in with a brush.

[James Moss]

For the Tinted Visor , I used uncut car window tint film, that I perchased for $1.75 a foot , on ebay from the seller ( NuSolis ) Great product , works perfect for this application

[sahirate]

Awesome job for it being cardboard! I made a practice helm using these same templates and now I'm trying to use the base templates for a scratch build. I'm using a 5$ baseball helm for the dome ( cut off all the access from the dome itsself ) and using komatex PVC board ( same thing as sintra just different name brand )to mold it for the t-visor area to create the rest of the helm and going from there. Hopefully it turns out as awesome as your cardboard build!!! =)

[geekynerd]

Very nice, but is the back supposed to be like that?

[Honus]

Yep- that's what it's supposed to look like.

[geekynerd]

Shouldn't it be kinda more tarnished? If that makes any sense

[Honus]

No- it's pretty close from what I remember. I did a bunch of research on The Dented Helmet website.

[RetroSpecter]

Impressive. Obi Wan has taught you well.

[Honus]

Thanks! The reality is that in hard core SW costuming circles I'm still a Padawan.... but I probably have less money in an entire Fett costume than other people have in their ammo belt. :)

[RetroSpecter]

In today's economy, I'd say that means you're a Jedi Master using what you've got. ;)

[qwerty12533]

it looks so good when its finished you would never know it was cardboard

[renscan2]

Where do you get the templates? I know they are on the dented helmet website but is there like a forum to go to?

[Honus]

You can download the templates right here on the first page.

[renscan2]

Thanks!

[HalloweenJuNkY]

I figured out the templates thank you and this was a life saver I have to make about 20 of these for a project I'm working on, and you just saved me a lot of time and money. -Miranda

[Honus]

Cool- glad everything worked out. 20 helmets- wow! You're going to be very busy...

[HalloweenJuNkY]

That's not the half of it I'm the production Director for the project I'm working on as well as designer, co-writer, Animatronic builder and operator, actor, and post production supervisor. so you really have no idea how much you've helped me. But I'm doing what I love so it's all good . And Thank You So much. -Miranda

[plokko]

i want that!

[drooch]

I would like to know, how to you make the 'Scratches effect ?

[Honus]

All the scratches were just painted on.

[xevoz44]

do you have a template for the rocketeer?

[Honus]

Nope- not yet! I'm still working on it so it's going to be a while before it's finished.

[Gears117]

What kind of paint did you use, and do you coat it again with Polycrylic sealer after the painting is done so it wont scratch off?

[Honus]

I used acrylic paint- I didn't coat it afterwards.

[erisdelphi]

this is uber amazorzaurus rex. you would not even think it was cardboard! can you elaborate a little on how you make the paint look all flaked off? do you really put a metallic coat on under it? the dent is like the most awesome dent i ever saw.

[~INVENTOR~]

This is an amazing job u did!!!!! i love star wars

[Magnum764]

Hey thanks! Great job but I'm a little stumped. I don't know if anyone has already asked this but what color paint did you use? And what color Like was it Army Green or Lime green? If you could just let me know because I'm not sure what to use. Thank You for the great instructions! Magnum764-

[Honus]

The main part of the helmet is an Olive Drab green with the back a bright green and the cheekbone section are a darker green. I don't remember the exact names of the colors I used.

[Magnum764]

Great! Thanks a lot that really helped! Keep it up!

[lastspartan00]

Great job on this, it was very helpful while I was making my own helmet.

And I know it is a small detail, and probably not important to you, but the larger red area is supposed to be above the key slots instead of below. Just a heads up. =P

[eden316]

hi.. have any idea how to make an iron man version?

[Honus]

I'm working on it! I know people have done this using Pepakura Designer- that's the route I'm taking.

[kwally89]

I was wondering how you cut the visor out. I started using plexiglass with limo tint on it, but it failed. I then changed to the polycarbonate clear faceshield with tint. The curve is perfect, but I'm a little nervous to cut it as the plexiglass cracked.

[Honus]

I cut the visor material using scissors- it was really easy to cut as it's kind of soft/flexible.

[sixarmspiderman]

where do you get the visor plastic at,where do you get that kind of cardboard.The temples I downloaded are they size for most adults? Thanks For Your Time

[Honus]

I just used a plastic faceshield I got from the hardware store and I used some stick on window tint from Autozone. The templates are the correct size for most adults. It looks huge at first but it's the correct size as it's the same as the original movie helmet.

[zemmy]

Dude this is so awesome, how do you do it Honus

[darth energy]

what is the material thats used for the visor called ? and where can you get it ?

[Honus]

I made the visor from some clear flexible plastic sheet that I had- you could cut up one of those clear plastic face shields. I used some stick on auto window tinting to tint it. They sell rolls of it at places like AutoZone and Pep Boys.

As an alternative- you can order a dark green faceshield from RJ Safety
The one you want is EAL22667 - Dark Green Faceshield

[kirwandp]

realy nice, planning on makeing one, one question though, why cant i use corregated card board, if the time is taken, wouldnt it be possible to hide the edges, and for the view finder, could i put an actual set of lences in there? thanks for your time

[joedurand]

harder to bend and shape. I just built this last weekend and there are some things that you do not see or get clear directions on in the templates. Some of the items could be better built in one piece so all you have to do is score the board and fold.

[joedurand]

...not to say what he has supplied is not great. The CAD templates rule! The cheeks and crown would be impossible without them. J

[Honus]

You can try corregated cardboard but it's difficult to bend it and get a smooth surface. As for the viewfinder, you can use clear acrylic for the lenses. If you have any more questions just let me know- thanks!

[hatae55]

u could try taking apart the cardboard and layering it w/o the corrugations... just a thought :)

[brassneck]

Excellent project. For a newbie in the uk, what is spackling paste?

[Honus]

Spackling paste is basically a drywall paste- what you use for patching holes in walls.

[starwarsmommy]

This is amazing!!--Can you tell me about how long this takes in its entirety, and how I could make it small enough for a six year old?

[Awsomechenie]

u like star wars?

[Honus]

How long it takes depends a lot on your skill level- I probably made it in under a week. You can make it smaller by printng out the templates smaller. If your child's head is two thirds as big as yours then simply reduce the templates to print at 66%- there's really no direct formula but at least that will get you in the ballpark.

[artistolipto]

awesome my cousins love halo 2 could you make an instrctable on how to make a master chief helmet i wanna make one for they're birthday!

[Honus]

I do have plans for another cardboard helmet instructable that shows a different method of construction- it's not a Halo helmet but a lot of the same techniques would apply. Stay tuned!

[andrew.mac]

Do you think i could make a King Leonidas helmet from 300

[Honus]

That would be awesome! Go for it- make sure you post photos when it's done!

[cksaint]

Awesome!! where did you get the foam padding though? I have been looking forever!

[Panton6]

You can also get the foam from your bike helmet. I know im going to use mine. If I ever make a helmet thing.

[Honus]

I got it from some leftover packaging but you might try craft stores or fabric stores.

[brianroesch]

Great job on this!!!

[peacefrog226]

where did you get the cardboard? ive been looking everwhere!

[Honus]

It's available at craft/art stores like Hobby Lobby. It's called newspaper board.

[thesparine]

Fuck yeah!

[Thorgo1]

it looks like boba fett

[IamTheCreator]

Just one question, where are the eye holes?

[IamTheCreator]

Make a halo helmet!!!

[IamTheCreator]

I like how you put the alien characters and how it's all worn out like the real Boba Fett's helmet; Lots of authenticity! Please make more star wars helmets. I suggest Sandtroopers, one of the aliens, Jango Fett, and maybe a starfighter pilot helmet. Thanks for the tutorial!

[lilb0yb1ue]

holy crap, make a mega man costume! pleeeeeeeease!

[Stormdrane]

Awesome job!