Introduction: Luke Skywalker Helmet (Rebel X Wing Helmet)

My son really wanted to wear one of those cheap costumes that come with a plastic mask but he was a bit dissappointed that it was too shabby so I decided to make a helmet for him on a budget.

And yes, I am aware the overall is Poe Dameron's and the Helmet is Luke's, lets just.... OK?

I saw a video that gave me this idea, I will look for it and post it just in case you need more details.

Step 1: Get a Baseball Helmet and Cut the Visor Thingy.

I got this one from the Goodwill store for 4 dollars, it was covered in stickers but other than that it was a perfect fit and had the perfect shape, this is a Rawlings Softball helmet I think, it also had the face mask that I had to discard.

I could've done a better job with a dremel but I do not own one so I had to use a drill to make a line of holes and then just rip the part off, I also had to use a file to remove the sharp edge.

Step 2: The Curve on Top of the Helmet.

I originally wanted to make this out of eva foam but I had none left and I wanted to make this project as cheap as I could so I went for the almighty cardboard.

I forgot to take pictures of the process but it is basically a rectangle, make 3/4 of an inch flaps and fold them to create the shape and make some cuts every half inch or so just to force the carboard to bend, I used a dab of hot glue on each fold to make it firm.

Step 3: Glue the Cardboard Piece to the Helmet.

At this point it looks like a roman hoplite helmet.

Just find the center of the helmet and paste it with as much hot glue as you want/need.

Notice that the carboard piece is not rectangular all the way into the back, just cut the flap to match it with your helmet's shape.

Step 4: Prep for Painting.

Notice that I missed the center, I also used some tape to secure it to the helmet while the glue was drying.

As I mentioned this helmet was utterly covered in stickers, make sure it is totally clean and free of adhesives or dust before painting it.

I found a broken phone headset that kinda looked like a mic so I will add that at the end with hot glue.

Step 5: White Primer.

I got a can of white primer for 3.50 at Walmart and I used probably half.

Make sure you cover the inner areas with tape or the sponges will absorb a LOT of paint.

Step 6: Design and Details.

This is the hardest part for me, I had to freehand most of the design with a pencil while looking at images of the helmet in google, I used a Black sharpie and a Red one to create the basic design, you can go the extra mile by "decaling" the design and maybe spraying.

I had some security goggles laying around so I repurposed them and glued them into the rim of the helmet, I KNOW the resistance has yellow tinted visors but I had to improvise.

I am also missing a few details such as the yellow lines but I could not find a suitable yellow marker, you can see that the one I used was already fading out but my son is not so picky about that.

Halloween Costume Contest 2016

Participated in the
Halloween Costume Contest 2016

Hats and Headpieces Challenge

Participated in the
Hats and Headpieces Challenge