Picture of Paper Stormtrooper Helmet
This instructable will show you how to make a scale stormtrooper helmet out of paper.

i made mine for halloween

it took me almost 40 hours

and only cost me about 16 dollars.
(more or less for you, i had some things already, you might be abe to make it for less!) (or moar, beware!!)

thanks and enjoy!
lots of feedback pleasee!

Step 1: Gathering of matierials

*Pepakura viewer (the english version is best, unless you want to translate japanese to navigate it found here

*this stormtrooper helmet 3d pepakura file.:
found here

*a printer with at least 27 sheets of paper.

*2-3 sheets of posterboard (i used #180 drawing paper)


*a razorknife/utility knife

*a glue stick

*super glue

*bondo or sheetrock brand drywall filler

*assorted grits of sandpaper from 60 to 600

*white gloss spraypaint

*black sharpie/ black marker

*silver/grey marker

  • a square foot of aluminum window screen

  • two sink aerators with screens (yaknow, the things on sinks that makes the water come out nice)

(dont steal them though)

  • about 40 hours of spare time

*the incentive to make a sweet stormtrooper helmet on the cheap.

okay, lets get started.......................
Good job, but u can agree a little more dedications!!! and will be ok!!
Travpena4 years ago
wait your saying that really long piece is all one piece?
pocdragon (author)  Travpena4 years ago
yes, the long curved pieces are a single piece for the brim

in the pepekura program you can highlight the image of wheat was printed and it will show you the brim hilighted on the 3d helmet model

the best thing to do is print outeverything at once, cut out the little pieces around the brim that you need
and toss the brim

its going to take a good deal of time to make the brim how the program wants you to

save yourself the 10 hours of delicate work and nix the brim and sharpie it on
Travpena4 years ago
why dose the PDO file have like 5 or 6 pieces stuck together?
if its just me HALP!!!
pocdragon (author)  Travpena4 years ago
yes the really long spidery pieces are supposed to be the eyebrow section

you can:

a) continue witht the helmet as planned but you would have to cut outall those super skinny pieces and wedges to glue with

b) like i did and just sharpied the eyebrow onto the helmet
i did not make the eyebrow piece because it is very complex

and all it makes is a rectangle that arces above the eyes haha
so really its not needed?
pocdragon (author) 5 years ago
thats a sweet starwars fact! thanks for checking out my instructable!
dudeishfish5 years ago
Those chrome thingies were microphones in the actual movie. In case one of the stormtroopers needed to talk, those holes were big enough to fit a mic inside.
ScareDeeKat5 years ago
Ohh, thanks a lot for this ^^ been looking for a pepakura ST for a while to go with my fem-armour as the bought ones are too big. Thanks again!

The template can also be found here for those having trouble  ^^  http://myweb.wit.edu/jacksons2/Stormtrooper.htm
pocdragon (author)  ScareDeeKat5 years ago
glad to help!
mize965 years ago
 put the link of this helmet
pocdragon (author)  mize965 years ago

all the links are step one
qwerty125336 years ago
how do you find the template?
pocdragon (author)  qwerty125336 years ago
in step one, it says " download the stormtrooper template here. and the word "here" is in blue. click on the word and it will take you to the site i have it saved to. the site only has a short sentence on it, where you click another blue word and the template will download to your desktop. the file is a RAR file, so after downloading, use a program like WinRar to extract the file. (right click, extract here) then (if you have pepakura installed) open the extracted file with pepakura and there ya go.
hi . can you put the file here..? thx in advance
pocdragon (author)  vallesan6 years ago
the files are on the step one page just read and follow the link, all the links work
sorry about that .. i speak little English ... BTW thx so much for the helmet, i was looking for this file long time .. i will post my pics of the trooper helmet and my head ..i finish my own head in pepakura and facegen..
mineral-26 years ago
Most people might have trouble learning how to do pepakura. (jez halo helmet only needs 21 pages) other than that thx.
pocdragon (author)  mineral-26 years ago
i tryed to describe the use of the program in as much of a vernacular as possible. i found out about the program and dove right into this project with no prior experience without any help, so it shouldent be too hard for other "avarage joes" to pick it up the "halo" master chief helmet is much more boxy then a stormie helmet. when pepekura makes a modle of somthing it translates it into polygons. with the storm trooper helmet being exclusivly curved surfaces it makes it much more complicated, but not to the point of being hard. i have also made the master chief helmet and it is much the same difficulty, this project however, just takes more time. if you downloaded the stormie model, you can see that the "brim" part (the black stripe above the eyes) takes up alot of page surface. this is because its made in long winding strips, but in general volume sense the helmates use about the same amount of paper. the stormtrooper one is just 100X cooler thanks!
Do you know of a similar program that is mac compatible?
If you look in step six, I believe he is running Pepakura on his mac.. :D
nope, his laptop has two mouse keys. and the program won't open on my mac ):
you can use any mouse with a mac...
I'm way late on this argument but in step 6 in the first pic you can see the windows sticker in the bottom left corner
lol what I was saying was his computer has two mouse keys, and macs only have one; therefore, he is not running the program on a mac.
pocdragon (author)  Aleksandr Skotbot6 years ago
no, thats not a sure fire way to know. you can get a mouse that has two click features (or more) and stil run OSX. just walk into staples and look around, the right click just doesnt do anything.
right click works on macs. if you dont have a 2 button mouse, hold control and click and you get the right click menu thing.
he is saying that his laptop itself has two keys. there is no mouse involved here.

Also nice job on the mask =p
it appears to be an IBM thinkpad. I'd also be interested in a mac or linux version
pocdragon (author)  Aleksandr Skotbot6 years ago
im sorry, i do not. =[
zeroxred6 years ago
the design is very detailed. Amazing! My question is how did you fit your head through it? lol. I'm almost done building and the opening is very small.
pocdragon (author)  zeroxred6 years ago
hello , and thankyou for replying! very good question, i completly for got to mention that. haha, i updated step 9 under EDIT any other questions i would be happy to answer please send me pictures of your helmet when your done!
zeroxred6 years ago
Do you think the helmet would be strong enough if I just make it out of paper and not poster board?
pocdragon (author)  zeroxred6 years ago
to use as a helmet? no the paper wont beable to hold up when you use the filler on it. it would collapse on itself, sorry! if you have a budget to buy a good deal more poster board, you can cutit into 8.5X11 sheets and print on the posterboard.
mokano6676 years ago
this would be easyer stronger and better looking if u hade used poster board, fiber glass sheets and epoxy resign
pocdragon (author)  mokano6676 years ago
yes, your correct. but this is not a "fiberglass stormtrooper helmet" its a "paper stormtrooper helmet"
KentsOkay6 years ago
pocdragon (author) 6 years ago
i believe the zune in the step six picture can be the deal breaker, its not a mac haha
pocdragon (author) 6 years ago
unfortunately, I'm not really running a mac. its just a very elaborate skin. sorry mac users!