Making BIG Lego Darth Vader




First of all I have to say : THIS IS NOT MY IDEA. The idea comes from this guy

I thought it looks awesome and I decided to make it. Mine is a bit smaller about 26 cm. But for me he has it complicated so I thought about making it on my own and IT WORKED.

but there are some problems : I wasn't sure if it will look nice so I do not have almost any pictures of making it so I will try to explain it. Another problem is I wanted to make shiny helmet and it is so shiny that my camera doesn't take it but in real it looks super cool.

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Step 1: Step 1 : Materials, Tools...

-Software requirements (like your skills) : basics of geometry (perimeter, area of square, circle, rectangle), how to use knife and scissors and not to cut yourself, knowing how to use calliper

Hardware requirements (like tools If you don't know -_- )This figure is (except lightsaber) made entirely from harder paper than usual.(I used A3)

-Tools I used :



some other measuring tools like RULER, PROTRACTOR, COMPASSES



GLUE (I used glue for paper that turns transparent after hardening)

Step 2: Step 2 : Thinking

First I did was : I found 2 pieces of paper tubes that slides together easily.

Than I measured neck of figure with calliper and the smaller tube. I divided it and get the number 6 - it is VERY important.

Now everything you do you have to do it in 1:6 scale - that means you have to enlarge it 6 times to get the wanted result.

I did this on the picture above - I draw every single piece of the lego figure 2x - first one has measurements of real figure and the second one has it 6 times bigger. ( you might want to measure it yourself because here it is not readible).

Now it's finally time to make something.

Step 3: Step 3 : Head

First I made rectangle for the face it is in my case 3 cm x ((diameter * π(3.14) = 18.8)

I glued it to two tubes joined together and the top and bottom curved places are done by gluing triangles. But have everything measured properly - like the tubes sticking out.

Yeah, I know it doesn't look very well but if you have any solution how to make it both : easy and nice I will do it again.

Step 4: Step 4 : Body

Draw the bottom line ( 9,24 cm) now make a centre of this line and make hight (7,7 cm) throught this point. Now draw parallel (3,5 cm) line on the end of hight on both sides. Now join these lines and you have a part of body done.

To the bottom line draw two rectangles on both sides under 45° (4,8 cm x 7,7 cm). And make holes for arms. And a rectangle (9,24 cm x 4,8 cm) to bottom.

To the top line draw a rectagle (7 cm x 4,8 cm) with hole in the middle for tube (neck).

To this rectangle- on top- make the same shape like this "Draw the bottom line ( 9,24 cm) now make a centre of this line and make hight (7,7 cm) throught this point. Now draw parallel (3,5 cm) line on the end of hight on both sides." but turned in 180° for back but I didn't glued it to rest of the body because of next steps.

Step 5: Step 5 : Arms, Hands, Legs, Cloak

For arms I just glued those two tubes together under a small angle.

For hands, legs, cloak just use your geometry skills and mathematics. Be independent - and remember I did it - You will do it too. Don't follow everything like sheep and show your self you can make it on your own. I know this page is about showing people thing and how to do them but I think I'm not able to explain everything I did to you - it is even harder because my mother language is Czech.

Step 6: Step : 6 Lightsaber

Lightsaber is just a tube with several tubes glued on top of it in layers. It is all covered in aluminium duct tape. And the "laser" is made from red foil rolled in tube and secured with duct tape.

Step 7: Step 7 : Helmet

For helmet I used some kind of plastic cup that fits on head perfectly.

Than I tooked a piece of paper and using the method of " try and fail " I finally got the rest of the helmet - really I just cut out a piece of paper and it didn't work so I cut out another.

But as I said: I do not have any templates because I wasn't sure if it will be success or disaster.

Step 8: Step 8 : Painting

Before painting I covered everything in paper dipped in glue for reinforcement and make the helmet round on top.

For this step I have to thank my father - he did this amazing job - head to grey colour, helmet to shiny black and the rest dull black. (the helmet still doesn't look good on photos but in real life it looks awesome)

Than I used silver, black, green and red marker and did the details according to my hand made templates I cut out. (the red and green marker might not be visible on the body- that's why I used coloured sticker.

Step 9: Step 9 : Glowing Lightsaber

First I made a "ladder" of 5 parallel join LEDs.(you might want to use some resistors about 100 Ohm to the LEDs last longer). Than make socket to lightsaber to be removable with wires sticking out of the top - these are soldered to the " ladder" and the foil goes over.

Battery holder with switch goes into the body and the wires throught arm and hand where they are sticking out, waiting to be joined to lightsaber.

The last picture is a short test.

Step 10: Pictures

I hope you enjoyed it. And if you have time try it!.... it is easier than you think. If you have any questions feel free to ask me down below and I will try to answer it. Thanks for attention and I hope you will show me your lego figures.

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    16 Discussions


    5 years ago

    No Luke I am your father


    5 years ago

    Wait if it's not your idea then how can you use it but forget that this is awesome!!!

    1 reply

    Reply 5 years ago

    Yeah this is not my idea, but I did it on my own I just didn't got the thought of making big paper lego figure. Why I couldn't use it ?? If someone makes e.g. bracelet, chair, robot, battery or ironman costume - it's done all the time - and someone else make the same thing but different way - he also can't share it ? (didn't mean to be offensive but I just want to make sure ..).And thank you ...


    5 years ago on Introduction

    Looks great! I have a Darth Vader Lego Clock reminds me of him, so I think you did a pretty amazing job if I think it looks like something that was manufactured by Lego. :) I think you are being hard on yourself about your head. However, a good way to help get that round look, would be to cut strips and then hook the strips together. There is a great template here that lets you make a paper craft mini fig, I think you could alter the head for your vader.

    All that said it really does look great, we are always our own worst critict and we are all always learning. I hope you do make more, I would love to see how you contiune to build on your process. :)

    2 replies

    Reply 5 years ago on Introduction

    Nice links ! Thank you. Maybe I will try something like this - it looks great ! I saw your Instructables and I think you definitely gonna make it.


    5 years ago on Introduction

    Excellent! As the guy that made the other one, I have to say this is quite impressive! I know how much work this represents.

    I love that you included LEDs to make the light saber glow. That's a great touch! You've definitely plenty of skill. Keep making stuff and never stop learning how to do new things. I can't wait to see what you make next!

    3 replies

    Reply 5 years ago on Introduction

    Thank you very much. And thank you for the excelent job you did. First time I saw it I said I have to do it no matter what. And I have to say that your work had to be even more difficult because you have everything like the right lego figure .. and the accuracy.... My Vader has some "improvements" so I have had it easier to make and there are some mistakes (fortunately not so many). I can't imagine to give something like this to anyone else's hands.


    Reply 5 years ago on Introduction

    I know, right!? I've had people want to buy mine, but I have to tell them it's just worth too much to me to sell it. And for me to make a new one to sell, it just takes too long for it to be worth it for them!

    With that in mind, however, I'm working on another jumbo Lego minifig right now that is carved from thick pieces of foam, which may be easier to duplicate than the paper version. I'm trying to make plans to go a long with it too. So maybe in a month or two I'll be done and post it!

    Anyhow, it made my day to see your BIG Darth Vader! Keep up the good work!


    Reply 5 years ago on Introduction

    I think I could but this one was enough for me for a long time and after that I thought about Imperial Guard from Star Wars. But as I said enough of paper lego for a long time.