Step 13: Vader's helmet

Darth Vader's helmet was made with cardboard, various glues, wood filler, and paint.

If you're interested in making one, there is a pattern of the main helmet piece included in the PDF in step 11. This is the piece shown in the second and third photos here (the attached pattern includes some changes that I had to make along the way with mine. That's why it appears slightly different than the piece in my photos).

Once you have this piece glued together, you will need to piece together a dome structure, and then slather it with putty or wood filler.

When it is dry you can sand it down to the shape you want. Mine needed a few filling and sanding sessions to fill in all the cracks and bubbles in order to create a smooth finish.

For the face section, I added little pieces here and there through trial and error until I got the results I wanted.

I gave the helmet a few coats of primer, lightly sanding between coats. The face got a coating of flat black paint, and the helmet got a coat of gloss black. The eyes were touched up with gloss black, and silver details were added.

The last thing I did was glue a piece of fabric around the inside so the jagged cardboard edges wouldn't snag on the figure's fuzzy head when you pull in on and off.
i finally finished a couple of weeks ago.&nbsp; thanks so much for the idea and the patterns you provided, i'm really happy with the way it turned out!<br />
Yea! Somebody made one!<br /> <br /> That's awesome--it looks great. You got all the little details done quite nicely, too. This makes my day.&nbsp; Way to go! &nbsp;&nbsp; &nbsp;&nbsp; <br />
<p>you did an awesome job you have the coolest insructables ever thanks alo</p>
<strong><em>What type of the cloth material did u use??</em></strong> <strong><em>And cud u tell us how did u made the </em></strong><strong><em>Vader's belt and shoulder pieces, and face and the helmet detail ?? cud u pls!!!! ur kindly<br> &nbsp;<br> <br> Macboy98 :)</em></strong><br> <br>
I used fleece for the bodies and heads, and some cotton scraps for Vader's cloaks. <br><br>For Vader's helmet, belt, and shoulder pieces, I used bits of thin, single-ply cardboard to build up each piece. If you examine the photos carefully, you can see what the pieces were made of, and how they went together. I used regular white glue to glue them together. I do not have a pattern for any of these parts, as they were all made through trial and error.
<strong><em>Thank you for Replyin!!!!!!!!!!!!!!!!!!!!!!!!! :D</em></strong>
i appreciate all the work and detail doing into each of these, especially darth vader's helmet. thats very neat! :D<br />
Thanks!&nbsp; They were lots of fun.<br />
hey how that helmet do in the vaders bodie its big pls answer i dont know how
The upper section of Vader's helmet was pieced together through trial and error using hot glue and thin cardboard. <br><br>It was a tricky process, and I apologize that I don't have any more photos to share.
hey can you post a picture for making dark vader helm the upper part
mine looked like a 5 legged black monster.
Nice ideas. It's a really cool instructable 10* (I'll try to do 10 star...)
That's just awesome!! I just taught my 9 year old how to sew an army pillow... I'm seeing bright things in his future now :-)
my sister would love these!
This is so cute, I would make one, but I doubt it will turn out right :P.
you made an awsome work, but where's the darth vader's helmet pdf? the pdf on step 11 only shows the first piece. thank you, keep doing it great.
I'm glad you liked this!<br /> <br /> I might not have stated it clear enough... that main piece that I've included in the PDF is all I have to offer. The rest will have to be done on your own. It kind of sucks, but there was so much trial and error involved that I wasn't able to produce patterns for the entire thing. Since the helmet is basically a sculpture, duplicating it on your own will require a good eye, patience, and a lot of determination.<br /> <br /> I&nbsp;felt the most useful thing I could do was share the piece that I started with, and at least get people headed in the right direction. <br />
nice! im goin to make a Domo plush!<br />
Kool, Im gonna try it<br /> thanks<br /> P.S. I will tell u if I poke my eye out<br />
Those look like something you'd find at a store!&nbsp;Very professional. Makes me wish I&nbsp;could sew without injuring myself and surrounding others.<br />
you should micro size them
Micro size them? How small are you thinking?
i dont know but maybe like 5 inches tall and 3 inches wide
i love and collect tiny stuffed animals. get me a picture!
My kid asked for a Yoda one, and about 5 inches tall would be just the right size to go along with Vader. Hmm...
ok and congrats on the gorilla glue cardboard contest
wow great instructable......i made one, however i did not have a sewing machine and had to do it by hand.it turned out good with a purple body and a blue mask and a jedi sord of coat.......i wish i had a camera so i could post a pic
Insane detail, how'd you make the buttons?
The buttons are just little tiny pieces of cardboard glued on to the bigger piece of cardboard with white glue. I was kind of scared off by these little details at first, but they weren't near as hard as the appear. I spray painted all the pieces black, and then added details with enamel model paint.
wow, you're good! you could really do a lil business out of it. You would really do fine, I'm sure.
You could use the shell for a helmet. Just a thought.
AMAZING!!! I'm making a Donatello as soon as I can!
That's what I like to hear! Please post a picture when you get it done!
That is flippin' amazing!
theres no helmet plan, can anibady helme? Thanks a lot!!
The third page of the "vader cloaks and helmet" PDF is the pattern for the lower half of Darth Vader's helmet. This pattern is for the piece shown in the second and third photos in step 13. You will need to use stiff, single-ply cardboard. I don't have any additional drawn out plans for completing the helmet. I had to sculpt, shape, and continually modify the helmet through trial and error along the way to get the results shown. To duplicate it, you will need to do quite a bit of sculpting and eyeballing on your own. The pattern for that main helmet piece should at least get you going in the right direction. Good luck!
100% sure you're going to win the contest with this Instructable. 5/5 stars!
sh£$%" that mask must have been hard to make
mine came out really really creepy looking:(
That's okay. (Is it creepy good, or creepy bad?) The real question is, did you learn anything new while you were making it? If so, it was a success no matter how it turned out!
This is awesome!!!
sorry but I cant find the helmet in the pdf, it only have 3 pag....... Can U put in again? Thanks a lot! ;)
looks like something you would buy in a store! great job!
Thank you!
those are both amazing! great job and great instrucable

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Bio: I got an old sewing machine when I was just a kid, and I've been hooked on making stuff ever since. My name is ... More »
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