Introduction: Stormtrooper Helmet ( on a Budget)

Picture of Stormtrooper Helmet ( on a Budget)

I've redone this instructables because there was a problem with the last one, it only showed the first step, hope this works as it wouldn't let me edit the last one!

Step 1: Pepakura

Picture of Pepakura

Step 2: Resin

Picture of Resin

Step 3: Bonds

Picture of Bonds

Step 4: Sanding

Picture of Sanding

Step 5: Painting

Picture of Painting

Step 6: Detailing

Picture of Detailing

Step 7: Finished........ for Now

Picture of Finished........ for Now


GumiM (author)2016-04-19

what are the scaling/measurements of the head for this??

InnK (author)2016-02-05

how do you get a smooth and even surface from Bondo and sanding? I'm working on my Stormtrooper helmet now and I can't seem to get that. I'm using wood filler putty to substitute Bondo by the way

Joe_Bro117 (author)2016-01-13

Can you wear it???

curtis.newton.104203 (author)2015-11-06


can you tell me where do you find the black transparent plastic for the eyes ?


Pop the lenses out of some cheap large sunglasses

TarynS2 (author)2015-10-14

Can you please tell me the size of this Helmet when finished? Is it adult sized? I am hoping to make one to fit a four year old.

AlecTPR (author)2015-10-05

Excellent idea and I aim to try this in the very near future. The finish quality looks amazing on the images, but I assume that this is comparible to the amount of time you spend on it. Terrible usage of guitars though. lol

Not_Tasha (author)2015-03-08

I just wanted to confirm, is this a wearable helmet? Thanks!

matson23 (author)Not_Tasha2015-03-08

Hello, thanks for having a look, your right I don't say anywhere it's a full scale lid, but it is, it's 1:1 scale with a stormtrooper resin cast helmet ?

blackholeseeker (author)2015-02-06

That helmet looks like a movie quality prop! Great job and can u build a clonetrooper helmet the same way?

matson23 (author)blackholeseeker2015-02-14

Hey man, thanks, and yes you can build allsorts the same way, have a look at my other builds, they tell you more about pepakura as a Base to build on and the processes to make helmets

blackholeseeker (author)matson232015-03-03

Okay, thanks!

midsummermuse (author)2013-09-19

This looks REALLY GREAT for the materials and $ spent. You're too hard on yourself for a tenner project. :-) I wonder if I could be SUPER cheap about it and do paper mache on top of the card base to stiffen it before painting. Then I'd have everything I need at home already for the white base...

matson23 (author)midsummermuse2015-02-14

Or woman! Lol sorry just seen your profile pic! But again great idea on the paper mache

matson23 (author)midsummermuse2015-02-14

Thanks man, and yeah paper mache would work, and maybe some cheap wood filler over the top to smooth it out would help too

Scifibeginer (author)2014-09-16

Hi, I was wondering if you would be willing to share the file as Spacecowboys file is no longer on 4shared. Thank you

matson23 (author)Scifibeginer2015-02-14

Hey, unfortunately I no longer have the file, but it you do a bit of digging on the you should be able to get hold of it

This is the current home of the Spacecowboy ANH helmet:

msantos49 (author)2015-02-13

Hi. Could you please explain to me a little bit better the Bonds process (what kind of materials you used, the brown mixture you made, etc)? That would help me a lot. The helmet looks great! Thank you

matson23 (author)msantos492015-02-13

Hey, bondo is car body filler, it's a two part apoxy you can buy, you mix a golf ball size bit of the brown stuff, with a pea size bit of the red stuff called hardener, you have a working time of about 5 minutes before it goes hard, once it's hard it's done, once it's hard you sand it, it's best to put it on in thin layers so your not sanding forever, the stuff I use is called p38 easy sand filler, you can get it in most diy shops or car repair shops, if you have a look at some of my other instructables you can see the process of putting it on and sanding, that's about it really, hope that helps!

shmyt (author)2013-09-12 I'm hooked... I guess I found my new time sink...
What kind of brands or names would this "Fibreglass Resin Pack" be under (home depot has been thoroughly unhelpful)? I have no idea what to really search for in terms of price gathering and estimates and whatnot (if it matters for shipping reasons I live in Canada).

matson23 (author)shmyt2013-09-12

Also I got a e-mail from you about the file but I can't find where you posted it so ill put the answer here! Haha, I had to search for ages, but I found it finally on, ( replica prop forum) I also had to sign up to 4share but that's ok because it's a trustworthy share site, that's the only one I would sign too to get the files, o and the best file to save you downloading loads of crap like I did, the best one is "anh stunt stormtrooper helmet" by spacecowboy.

Hope that helps too

matson23 (author)shmyt2013-09-12

If it helps the name of the fibreglass company is fastglas,it's in a yellow box, not sure if you can get it over in Canada but There must be something close to it,

matson23 (author)2013-08-06

Hi rambler,
Yeah the build was about £10, I already had resin ( I used a fibreglass resin pack, mixed and put on to the card without the fibreglass sheets, putting it straight onto the card makes it stiff enough I though, I got the fibreglass pack from a hardware shop a while ago,) as for issues with the tape, none at all, once the resin goes off its pretty much covered for bondo so the tape doesn't affect much, I wasn't aware of and issues before hand to be honest, and I've had no problem before and I've used this technic a few time now. Most of the cost was the bondo (£6) then card and I used what paint I had, the other cost was cheap brushes for the resin, that's about it, everything else I used what I had, left over stuff and what I could scavenge haha, the lids not perfect but it's an on going thing, I want to strip it back a bit and resand it for a better finish, then spray paint it instead of brushing, hope this answers some questions for you! Thanks for checking it out!

The Rambler (author)matson232013-09-03

Awesome, thanks man. I went ahead and threw some masking tape on a few spots on one of the helmets I'm working on. Haha I figured, meh, what's the worst that could happen? Good to know you've used it before and never had a problem.

I've been debating whether or not to try it without the fiberglass sheets, I think I might give it a go.

matson23 (author)The Rambler2013-09-03

Try it, if you resin the inside and outside and let it dry, it'll be fine because the bondo and stuff also stiffen it up too, but if after the resin your still not happy with it and it still moves to much, just glass the inside, it's never to late to but in that fibreglass on the inside right!?

Also I was thinking about your budget restrains and I too have to work to a budget, but if you can, try get a dermal craft tool, ( or whatever make you can get, I've got a draper one and it's just as good and half the price of a dermal) so very useful, fiddly sanding, little cutting, grinding, drilling, it'll make your life so much easier when making, I use it for allsorts, and if you can get one with a flexi drive shaft attachment, do it! Anyways that's something to look into if you want, happy making mate!

The Rambler (author)matson232013-09-04

I was so lucky to have a generous friend with a dremel he wasn't using! I was talking about how I wanted one and he said his dad gave him one and he never used it so he up and gave it to me! It has come in handy on so many projects. I do want to get one of those flex tools though. It seems like it would be so much more manageable. What kind of attachments do you use on your helmets? The sanding discs and some of the grinding wheels seem handy, but was there something in particular that you found really useful?

matson23 (author)The Rambler2013-09-04

The full thing is useful, the flexi drive shaft is very hand, special when your doing fiddly sanding on helmets, in hard to reach places, in the corner of eyes and curves etc, I use mine mainly for sanding bondo and fiddly work, but the cutting discs are great too, ( that's how I did the battle damage on the skyrim helmet) also pretty handy for cutting back over hanging set fibreglass and scuffing paint, detailing lines in stuff ( detail on the bottom of Thor's hammer, I used it with a cutting disc), all in all, brilliant bit of kit! Get the attachment mate, the flexi thing! Lol

The Rambler (author)matson232013-09-05

Well now I have to get it!

The Rambler (author)2013-08-06

A couple questions for you, You said this cost you about £10, did that include the cost of the resin and bondo or did you have that on hand already? Where did you get the resin? Also, I read that the type of adhesive used in some tapes can cause issues for the resin and bondo down the road (like deterioriation), but I think this was in reference to scotch tape. Did you read up on masking tape at all? Does it not have that issue?

poofrabbit (author)2013-07-27

This is just plain awesome! I now need to give this try.

el greeno (author)2013-07-17

Why have I never heard of pepakura before? I've been using all sorts of techniques to make costumes. This looks by far the easiest!

captain camo (author)2013-07-17

So epic!!!!!

DE4D POOL (author)2013-07-17

The original storm trooper armor was made by vacuum forming, it was one of the first use of vacuum formers

Honus (author)2013-07-17

Nice work!

matson23 (author)2013-07-17

Well, I did the instructable a week ago, but when it uploaded it must have bugged, because it only shown the first step, and it wouldn't let me edit it, so I screen grabbed what I could from my phone and re-did it instead of having to rewrite everything, thanks for looking!

Kiteman (author)2013-07-17

That's a nice job, but I've got to ask, why is all your text in images?

About This Instructable




Bio: im a fixer,hacker,maker and shaker
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