Instructables
Picture of LEGO Darth Vader!
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This is a 100% home-made LEGO Darth Vader costume, created using cardboard, papier mache, and spray paint. I bought a LEGO Darth Vader keychain from the LEGO store at the mall and used it to scale up the measurements and maintain the proportions. This costume is very easy on the wallet--I'd say about $50-75--but takes a lot of time and planning!

You can pick up leftover cardboard from Costco or BJs. You'll need to find big, flat panels for the chest piece. Creases in the middle will make things more difficult and ruin the look. You'll also have to find some kind of softer, more malleable cardboard to use for the curved part of the legs and the headpiece. This is imperative, because rigid cardboard will not work for these pieces. You'll need a good amount of black spraypaint for most of the costume. Also, one can of silver spraypaint, and some acrylic paint to do the design on the chest. The rest is good, old-fashioned elbow grease and a little creativity.

I took my body measurements and also all the dimensions of the little LEGO figure I bought, then tried to scale it up. Some things had to be modified to fit a human body, but I tried my best to keep the proportions as close as possible to the actual figure. The hands were cardboard reinforced by papier mache, and the headpiece was a cardboard frame (using that softer cardboard I mentioned) with lots of papier mache. I then used black pantyhose to cover the eyeholes and the ventilator. Add a leftover cape from a previous year's costume, and you've got yourself a LEGO Darth Vader!
19freemans11 months ago
Why not buy a full vader helmet save time and look da same
poofrabbit1 year ago
Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!
SlippingHalo (author)  poofrabbit1 year ago
Thank you!
Viva21 year ago
As Lego Princess Leia, we are destined to be archenemies, but I will say great job...wish I had done my legs more like yours! :)
SlippingHalo (author)  Viva21 year ago
Thanks! The legs were actually very difficult to walk in, so I ended up having to modify them later. Luckily I took photos before I had to mutilate them.
seamster1 year ago
Nice job! You need this to carry around with you when you wear your costume... your very own Lego Darth Mini-Me! 
SlippingHalo (author)  seamster1 year ago
Haha I totally should! Sorry for the late response. I didn't have internet for a while.
Katusha2 years ago
Nicely done!! Great paint job!
SlippingHalo (author)  Katusha2 years ago
Thanks! Those details were tricky. I'm glad you like how it turned out!
daikan2 years ago
Love it!
SlippingHalo (author)  daikan2 years ago
Thanks!
zomfibame2 years ago
nice!
SlippingHalo (author)  zomfibame2 years ago
Thanks!
Tomdf2 years ago
Awesome!
SlippingHalo (author)  Tomdf2 years ago
Thanks!
darrennie2 years ago
Brilliant.
SlippingHalo (author)  darrennie2 years ago
Much appreciated!
Honus2 years ago
Fantastic!
SlippingHalo (author)  Honus2 years ago
Thanks!
This is so cool
SlippingHalo (author)  TheAwesomestDude2 years ago
Thanks!
your welcome
Kiteman2 years ago
Oh, did you take any photos as you made it?
SlippingHalo (author)  Kiteman2 years ago
I did. Just added some.
Excellent - just what we needed.