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In this tutorial I will be showing you how to make a Star-Lord helmet from Guardians of the Galaxy using a pre-existing pepakura template (see step 1).

I encourage you to play with different techniques in this process.

This helmet is not meant to be 100% movie accurate.

Tools

  • Hot glue gun
  • Cutting board
  • Mat Knife
  • Small Putty Knife
  • Small Paint Brush
  • Hair Dryer (optional)
  • Scissors
  • Ruler

Materials

  • Thick Cardboard (shipping box)
  • Thin Cardboard (cereal box)
  • 1/4" Eva Foam
  • 1/16" Eva Foam
  • Paper Towel
  • Wallpaper Paste
  • 12 Gage Wire
  • Cardstock
  • Spot Putty
  • Mat Card
  • Filler Primer
  • Dark Steel Spray Paint (Rustoleum)
  • Gold Spray Paint (Krylon)
  • Silver Model Paint (Testors)
  • Flexible Plastic Straws (bendy straws)
  • 3/8" Dowel
  • Red Lighting Gel or Red Lenses
  • Spray Adhesive

Step 1: Source Material, Template and Print Settings

Source Material

Before moving to the template it is important to grab some images from the internet to better understand what the helmet looks like outside of the template.

Template

I have attached the template I used for my build.

I did not create this template and have used it as a guide. I picked up this specific template from JFcustom on www.therpf.com

Print Settings and Adjustments

Once the template is downloaded you will need to print it. The file size is larger than a standard printer page, using the poster setting on your printer will solve this problem.

The circumference of my head is 22 1/2" (570mm) and printing the template at 100% made a snug, but perfect fit. If you head is bigger/smaller than 22 1/2" (570mm) you can use this formula to determine what percentage your print size should be.

100 x (your head measurement in mm) = Value

Then...

Value/570mm = Print percentage

For example...

If you have a 600mm circumference your print percentage would be 105%

Once the template is printed you will need to tape or glue the seams together before you cut out your pieces.

*** As you build try on your helmet to ensure that it fits!

Step 2: Tracing and Preliminary Build

Helmet Shell

Before you begin remember that if you see a - - - - - - line on the template that indicates a mountain fold. A -- - -- - -- line indicates a valley fold. The best way to utilize these folds is to score them with a knife in the direction the fold will be.

Trace the template onto thick cardboard (an old shipping box will be sufficient) and use either a mat knife or scissors to cut each of the pieces out. Using hot glue and tape piece the helmet together leaving out the ears and brow portions of the mask. Once the shell of the helmet is complete test the fit on your head. If the helmet is too big trim the back pieces, if it is too small add cardboard spacers in the back. It is easiest to make both of these adjustments in the back. Once the shell was complete attach a 1/4" strip around the top edge of the helmet.

*** I used eva foam to reinforce a number of my helmet connections. This is optional and can be substituted with cardboard or tape.

Helmet Ears

Trace the ear template on to mat card and mount them onto 1/4" eva foam. To attach the ear cut a piece of cardboard that is slightly bigger than the mat card and attach to the inside of the helmet.

Helmet Brow

Trace the brow template onto 1/4" eva foam and cut it out. The brow and the side burn pieces should be separated. Test the brow to see if it fits and trim the edge to round it before hot glueing it down.

Step 3: Vents and Paper Maché

Paper Maché

Before attaching the tube vents to the helmet, paper maché the entire helmet with wallpaper paste and paper towel. Be sure to make the maché sit as close to the helmet as possible being careful to saturate the paper towel with wallpaper paste using a brush. Once this is dry connect the tubes to the helmet and the tubes to the vent connection with the flexible part of a drinking straw. *** I use wallpaper paste instead of a PVA or wood glue/water solution because it is more flexible.

Vent Pannel

Before attaching the vents the mouth piece needs to be solidified. Using paper towel and wall paper paste, paper maché the front portion of the mask. Once the maché is dry attach the vent pieces with hot glue.

Vent Connection

Build the front portion of the vent out of the thinner eva foam.

Helmet Tube Vents

*** I chose to not use the vent templates for my helmet build. I felt they were too small and decided to make the large vents 1 1/4" in diameter and the smaller vents 1".

To make the vents I cut two 1 1/4" diameter circles and two 1" circles out of thick cardboard. Using the circles as caps wrap the circles in the thinner cardboard to make a four tubes in total (two big and two small). Wrap the tubes in the thinner eva foam attaching them with spray adhesive to smooth them out.

Step 4: Primer, Panels, Eyes and Filler

Primer

I primed the helmet using a Rustoleum fill primer. This primer gets into all of the scratches and imperfections and builds up. This eliminate a lot of the sanding I had to do. When the maché is dry coat the helmet in two coats of primer.

Helmet Panels

The paper maché greatly alters the panels on the helmet making them less distinct, the primer will highlight this. The solution is to put new panels on top of the old ones.

The panels can be made from cardstock or thin cardboard and can be made from the same helmet shell templates. You will have to trim these new pieces to get as close a fit as possible. Before attaching the panels make sure to do a preliminary sand of the whole helmet.

Attach these panels with hot glue and paper maché the edges. The edges will be cleaned up with filler, primer and more sanding.

Primer, Filler and Sanding

Once the panels are attached coat the helmet in primer. When the primer dries you will be able to see and imperfections on the helmet. Using thin layers of spot putty cover any imperfections. Once the putty is dry sand the areas with heavy to fine sandpaper, prime and repeat as necessary.

Eyes

Once the panels are attached the eyes of the helmet can be attached. They are made from the thin cardboard and are attached with hot glue.

Step 5: Side Pieces and Connection Tubes

Side Pieces

The side pieces are made from flexible drinking straws. Use the lines on the straw to cut it in half. Cut the flexible part of the straw in a triangle shape and put the two flexible ends together using hot glue. Evenly space the side pieces on the helmet and coat them in primer.

Connection Tubes

The connection tubes are also made of flexible drinking straws. The connection between the ventilation tubes was made by cutting 1" length of 3/8" dowel at 45 degrees. Once these components are attached coat them in primer.

Step 6: Stripes, Front Tube and Details

Side and Back Stripes

The stripes are made from the thinner eva foam and are attached E6000 and then coated with primer.

*** I chose to use E6000 over hot glue because the adhesive was not sticking to the primer.

Front Tube

The tubes in the front of the mask are made from 12 gage electrical wire. following the edge of the mask bend the wire to fit. When the wire is the correct shape and size wrap card stock around the top end making it thicker. Hot glue this piece in place.

Details

Using Eva Foam cardstock and bits of lighter weight card create the details of the helmet. These details will give the helmet more visual impact.

Step 7: Paint

Paint

I decided to paint the helmet in a backwards order.

Once the helmet is primed spray the entire helmet gold. Using painters tape cover the pieces by the eyes and cheeks that would remain the gold colour. Once dry spray the helmet with dark steel coloured paint. Remove the tape once everything has completely dried.

Outline the stripe portions on the sides and back in tape, covering the remainder of the helmet in newspaper. Spray the strips with gold and remove the tape when the paint is dry.

The final step is to take silver model paint (for model cars etc...) and use a small brush to paint in the silver details.

Step 8: Lenses

Lenses (lighting gel version)

I had some red lighting gel (Rosco colour R26) that I cut into small circles and hot glued on the inside of the helmet. Working in theatre gives me access to this material at little to no cost. I would suggest if you can't find red gel to use red tinted sunglass lenses instead.

Lenses (Sunglass version)

I found a pair of red round sunglasses today and I thought I would try to use them instead.

Take the lenses out of the sunglass frames and lay the lense on a table making sure the curve of the concave is upright. Cover the front and back of the lenses with painters tape to protect the lense. Use the old gel lense as a template and trace the shape onto the tape.

Using a disk sander slowly shape the lense. Test the fit of the lenses until you are satisfied with how they look. Remove the tape and glue the lenses in with E6000, making sure to keep the glue off the visible part of the lense.

*** I prefer the sunglass version. They are brighter and clearer.

Step 9: The Finished Product

Once the lenses are in, your Star-Lord helmet is complete!

<p>Very Nice! I am going to comic con in september, and I am wanting to go as star lord, so I think I am going to try to build this. It is one of the best tutorials I have found, and I am excited to see if I can get mine to look as good as yours! Just one question though; where did you get the eva foam from, and how much did it cost? I have been having a hard time finding any. </p>
<p>Thanks for the compliment! </p><p>I get all of my foam from craft stores, specifically Michaels in Canada. If you are really stuck you can always check out TNT Costume Supply online: <a href="http://tntcosplaysupply.com/index.html">http://tntcosplaysupply.com/index.html</a></p><p>Hope this helps!</p>
<p>how much did this all cost?</p>
The spray paint was actually the most expensive part. I mostly used recycled cardboard.<br><br>If I had to crunch the numbers I would say it didn't cost more than $50.
<p>Mega build dude</p>
<p>nice</p>
<p>Looks awesome</p>
Hey this is a awesome build I look forward to building! Maybe you could do more star lord stuff! I think that would be even cooler!!!
Any recommendations?
<p>youtube and instructables= perfect. thanks.</p>
<p>nice! :)</p>
<p>Thanks man. Happy to see you on instructables!</p>
Hey by chance do you have the 3D file/ template?? I'm interested in 3D printing it so I would need the measurements
<p>Sorry I don't. </p>
nice job on this. it's fun to see what others are building.
Quick question.....what did you make the larger tubes on the front out of? I couldnt find my answer in the tutorial but I swear I went over it a million times, it was at 1am which could be a factor....anyways thank you for any type of response.
Since it is my first instructable I may have totally forgot to mention this.<br><br>Basically I made the tubes out of thin (cereal box) cardboard with the caps being made of thicker cardboard. Glued the piece together and then wrapped it in 1/8&quot; foam to smooth it out. <br><br>Hopefully that makes sense. Let me know if you need more info.
Yes! Thank you, howw did you get the ends closest to the mouth rounded? Did you just work the cardboard till it looked right?
<p>It's actually two pieces of thick cardboard stacked. The top circle is just a bit smaller than the bottom circle. I then sprayed the stack of circles with spray adhesive and worked 1/8&quot; EVA foam over it. Once it had adhered I trimmed the edges and hot glued it to the tubes.</p>
Awesome, thank you! This really is a great tutorial, very clear and very informative with great pictures! Other than the face tubes the tutorial answered all my questions!
Awesome, thank you! This really is a great tutorial, very clear and very informative with great pictures! Other than the face tubes the tutorial answered all my questions!
Awesome, thank you! This really is a great tutorial, very clear and very informative with great pictures! Other than the face tubes the tutorial answered all my questions!
Awesome, thank you! This really is a great tutorial, very clear and very informative with great pictures! Other than the face tubes the tutorial answered all my questions!
<p>Nice &quot;ible&quot;!!!</p>
<p>Nice &quot;ible&quot;!!!</p>
<p>Nice &quot;ible&quot;!!!</p>
<p>Nice &quot;ible&quot;!!!</p>
<p>Nice &quot;ible&quot;!!!</p>
<p>great work!</p>
<p>Awesome build man. I love this helmet.</p>
<p>Mind pointing out where piece eleven goes? is it even necessary? Great work though I think im going to use yours and Dali Lomo's tuts to make this thing :D</p>
<p>Sorry for the late response. You can find the image that shows piece #11 in step 3. I've attached the image that doesn't have the number. It's the black chin piece. Dali Lomo does great work. I would love to see what you come up with. </p>
I don't think I can do this. My helmet looks like crap and I just don't understand how yours is so smooth and thick. I just looked up your location to see if I paid you enough if I'd even get it in time. ...but you're too far away. I guess I'll keep plugging along.
<p>How much are you willing to pay? </p>
Ha ha ha. ..not much, that's my problem. $60 or so. I'm just gonna show up on your doorstep with my materials. :) im just resigning myself to the fact that mine will definitely look home made. :/
do you feel comfortable sending me some pictures through direct message? (not on this thread)
I will send you some when i get home. I kind of started improvising today cause I'm running out of time. So don't judge. ;)
<p>I got the template printed and cut out a few of them on cardboard but I am having trouble wrapping my brain around how to initially put it all together. Do you have any more detailed instructions or pictures of putting together the first cardboard pieces? The pieces that I have don't look the same as yours, specifically the front middle piece.</p>
<p>Changed some stuff up. Let me know if it makes things clearer. </p>
Thank you so much. That cleared it up perfectly. The only helmet I've ever attempted was a duct tape batman and it was a major fail. I'm making this one for my husband and if I screw it up I will ruin Halloween. :) I just finished my first paper mache layer and I'm trying to figure out the chin piece. It is labeled 11 but my piece looks nothing like what you've got going on. I'm trying not to be an idiot, but I'm a copier, no imagination. Tell me if I'm just being dense and I'll try to improvise as best I can. Also. ..I could not find black fill primer. Where did you purchase yours?
It's a really weird piece #11. When I get home I'll dig for a picture/put that piece together again and take a picture.
Thank you! And I figured out that the fill primer is grey and found it at home Depot. What is the black layer you have pictured?
Just black spray paint. That's a step you can skip. I wanted to make sure paint would stick and I hadn't bought the primer yet.
I appreciate the questions. It's helping me improve my tutorial. :)
Also will you just sell me yours? ;)
<p>I wouldn't be opposed to an offer on the piece. ;)</p>
I don't think I can afford your expertise. :/
<p>lol</p>
<p>so the grey is just the effect of the wallpaper paste or?</p>
<p>Wallpaper paste will dry clear. The grey is primer. I primed that helmet a lot. </p>

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