This is a 5 inch paper mache R2 dome.
Step 1: Dome form
I started by making a dome form out of foam board covered in masking tape, onto which a paper mache shell will be made and then removed once it is dry.
Step 2: Dome form
To make the form completely smooth and uniform, I covered the masking tape with a layer of paper mache and then numerous thin layers of wood filler, sanding and priming in between each coat.
Step 3: Paper mache dome
The paper mache dome was made by wrapping plastic wrap tightly over the smooth finished form and adding layers of paper mache to it. When the paper shell is dry it pops right off the form.
A metal ring was glued along the edge of the dome to strengthen it and a front eye piece made from foam board was added. The dome was then covered with another layer or two of paper mache.
Wood filler and primer were used much like on the form itself to create a finalized smooth shape.
Step 4: Base coat and details laid out
The base coat of paint is Rustoleum aluminum. Details were laid out in pencil.
Step 5: Details
All the details were painted on with blue craft paint.
Step 6: Black eye piece
The black eye piece was made with oven bake clay that was shaped, cooked, glued in place and painted black.
Step 7: Cut out details
Several places on the dome have cut out details. These were marked and then cut out with a hobby knife. Different backing pieces were created to glue in place behind the cut out areas.
Step 8: Lenses
Lenses were made out of rolled up and painted pieces of cardstock. These were then glued in place on the dome.
Step 9: Light and sounds
I bought an R2 toy on amazon for about 10 dollars, and stole its guts to use for light and sounds.