Here’s how to make a cheap costume mandalorian helmet out of cardboard. Helmets are usually one of the most difficult and expensive parts of a cool Halloween costume to make, so here’s a simple method I use. The methods I describe can be used to make almost any type of helmet, but I’m showing how to make a Star Wars Boba Fett helmet as an example – the rest of the Boba Fett costume is covered in another instructable.
The templates are intended for printing on 8.5″ x 11″ paper.
Step 1: Gathering Materials
You’ll need a cardboard sheet—ideally one that’s about 1/16 inch thick. Corrugated cardboard will not work; instead, use the kind that looks like paperboard. A newspaper board is what I used, and it comes in 30″x40″ sheets. Crescent and Arches make it, and it’s available at craft and picture framing stores. Ram Board has also been reported to work extremely well by some users.
White glue, sandpaper, a hot glue gun, lightweight spackling paste, an X-Acto knife, and Minwax Polycrylic sealer are also required. You can also search for Motorcycle Helmet Safety Ratings to get more information about helmets.
Step 2: Create The Base
In this example, I’ll build a Boba Fett helmet from the infamous Star Wars character, but these techniques can be applied to almost any helmet. Because the templates are designed to be printed on letter-size paper, open the files with a program like Adobe Acrobat and print them on letter-size paper. Cutting out the templates and taping the separate sheets together is the best way to work with them. I then used rubber cement to adhere them to the cardboard before cutting out all of the pieces with an X-Acto knife. You should also know about the reasons to wear a helmet that will save you.
The first step is to create the helmet base form. Helmet base helps establish the basic shape of the mandalorian helmet. Later on, we remove it after the process. We create this base by using templates from pages 4, 8, 11, and 12. Glue these patterns on pages 4 and 8 together by cutting a slot along the centerline in each piece and then fitting them together. Join the patterns on pages 11 and 12 and cut them from a single piece of cardboard before gluing that piece to the patterns on pages 4 and 8.
Make the inner helmet surface now. Cut out the patterns on pages 18, 14, 17, and 13, tape them together, and cut them from a single piece of cardboard. Now, wrap this single piece around the base form of the helmet. Using a misting spray bottle to dampen the cardboard slightly will make it easier to bend. Then I epoxy the back of the helmet’s joint.
Make The Outer Surface:
Construct the helmet’s outer surface in the same manner as the inner surface. This outer surface is wrapped around and glued to the inner surface. Once the glue has dried, cut out the cheekbone sections on the inner surface of the helmet, and make the cheekbone sections by gluing the cheekbone template parts together and bending and taking the cardboard into place with a glue gun. Use the glue gun only on the inside of the helmet. Then, smear white glue all over the outside of the helmet’s joints.
Step 3: Constructing The Dome Frame
To create the “dome” on top of the helmet, I first make a cardboard ring and glue it into the top of the helmet. It will provide something for the frame to attach to. Construct the dome frame from two interlocking cardboard semicircles. After that, glue them to the cardboard ring.
Step 4: Finishing The Dome
Make some long triangular cardboard wedges now. Begin by bending these as close to the dome frame’s curve. Begin by gluing the wedges to the frame with the hot glue gun, then gradually work your way to the center of each frame section. Take your time as there will be a lot of trimming and adjusting.
Finishing the helmet will be much easier if the dome curve is correct. After filling in the dome, smear white glue along all the seams on the outside of the helmet. At this point, you can see that I’ve also cut out the opening for the visor. Now, put that bucket on your head and make sure it fits properly.
Step 5: Finishing Touches
It is where the spackling paste comes in handy. Spread a thin layer of lightweight spackling paste over the helmet’s dome. Also apply it to any other areas which you need to smooth out. After it has dried, sand it to shape. It will most likely take at least a couple of applications to get everything looking right—especially if your helmet has a lot of compound curves.
Step 7: Finishing/painting
Apply a coat of Minwax Polycrylic sealer to the entire helmet. It will seal everything, make it much easier to paint your helmet, and help make it water-resistant. Then all you have to do is prime and paint your helmet! It takes a long time to paint a Boba Fett helmet.
Glue the visor glued in place. This visor is a tinted plastic. I used hot glue, but epoxy putty also works well and is probably stronger. I then added some foam to the inside of the helmet to make it fit my head better and keep it from flopping around.
In conclusion, we can say that it is very easy to make a Mandalorian helmet. Firstly, it is a very fun process. Secondly, we can use this cartoon helmet to teach reasons to wear a helmet to our kids.