Introduction: Build a Star Wars Boba Fett Plywood Wall Plaque

Allow me to preface...

Being a long-time Superman fan, I was happy to find out that a great-nephew (4 years old) was also a fan.  With that, I decided to make him a a superman emblem to hang on his wall.  With that done, all other great neices and nephews then wanted their own plaque as well (in various forms).  So, making the list brought about a number 26 different plaques to make.  So far, I have made 10 and try to make a new one once a week.

This instructable will show how to make a Star Wars Boba Fett helmet wall plaque.

Since I am making a lot of these in various forms from Boba Fett to Happy face flowers, I kept some ground rules in mind.
Keep price at a minimum and spend no more than $10 per plaque using current materials and paint, then buying extras needed.
Keep it simple enough to complete in a weeks time (about 4-5 hours actual work time)
Use plywood as a base material where possible.

Step 1: Get Your Concept Ready

I ask each neice or nephew who their favorite hero, character, thing is and then research that.  Boba Fett was easy to find. I just searched google images and found all the material I needed for the concept.  That concept being a face on view of Boba Fett's helmet.

As this nephew was a bit older, I wanted to spend some more time on this and try adding the battle scars. is a site dedicated to the building of Bobba Fett props and was indespensable in heping me find paint templates, close shots, etc. 

OK... I got the concept, now time to draw it up!  I took a good front view of the helmet and added it to photoshop.   I then start to crop areas of color to determine how the plywood will be cut and stacked to make the view I want.

After that, it was easy to see how the layers would be painted and stacked.  I then finished the concept and plan drawings with the battle scars to see the complete view of the drawn project.

Step 2: Make Your Templates

After I have the color plans ready, I then remove the color and make a black border around each piece needed.  This make a good template and saves on ink.  I then make each template into a pdf for printing.  I like to do this as it help make sure all of the templates print at the correct size.

Step 3: Cut the Pieces

Using 3/8" or 1/2" plywood (with good finished surfaces) I then transfer the template to the plywoood to cut.  Depending on the pieces, I sometimes double up the plwood and tape together to get exact cuts.  After cutting, I noticed that the dome area was kinda puny feeling with only one plywood layer so added another.  I made 2 so that I could practice the battle scaring.  I added little extra touches where I could such as the dent.

Step 4: Paint!

Once the peices are all cut out to my satisfaction, it's time to paint.  After getting the base paints in place and dried, I printed out some more templates for the battle scars.  The green paint I had was a little darker than I wanted so I did an overspray with white with good result.

Then, I printed out COLOR versions of the battle scars that I found at the dented helmet.  I printed a couple of each so that I could layer some of the paint.  I then cut out large areas of the stencils IE: silver and grey first to paint the grey and then cut another for the inside color for a layered effect.

I then placed some photo paper in the printer and printed out some of the details of the helmet IE: the decals found on the ear flaps, etc. these were then cut out and spray-glued into place. 

Step 5: Done!

You are only limited to your imagination on these.  On the Batman logo below I added some imitaion carbon fiber for the background and added some glow in the dark paint to the edges of the bat.  The peace signs used the photo paper and designs found online. 

If you would like a full psd or pdf set of any of the plaques that you've seen here, just message!


5-7- 11 - Here's the boba fett package in a zip file - The file is about 22 megs and contains the templates for cutting and color plates for battle damage. Only the decal page needs printed at high quality on photo paper if you have it.

Here is batman - a 6 meg PDF -