How to Make a Cardboard Costume Helmet 7 Steps with PicturesFor this example Im going to construct a Boba Fett helmet from the infamous Star Wars character but these techniques can be used to make almost any helmet. I was able to download some Fett helmet templates from the Dented Helmet forum. The templates are designed to be printed on letter size paper so just open the files with a program like Adobe Acrobat and print them so they fit on letter size paper. Download the free trial version below to get started. Doubleclick the downloaded file to install the software. The best way to work with the templates is to cut them out and tape the separate sheets together. I then glued them to the cardboard with some rubber cement and then cut out all the pieces with an X Acto knife. The first step is to make the form for the helmet base. This is used to help establish the basic helmet shape and is later removed from the helmet. The form is made from templates pages 4, 8, 1. The patterns on page 4 and 8 are glued together by cutting a slot in each piece on the center line and then fitting them together. Join the patterns on pages 1. Now make the inner helmet surface. This is done by cutting out the patterns on pages 1. This single piece is then wrapped around the helmet base form. Getting the cardboard slightly damp use a misting spray bottle will make it easier to bend. Star Wars Clone Pepakura Files Download' title='Star Wars Clone Pepakura Files Download' />Then I epoxy the joint at the back of the helmet. Next make the helmet outer surface it is made the same way as the inner surface and is wrapped around and glued to the inner surface. Bmw X5 E53 Service Manual Download. For this example Im going to construct a Boba Fett helmet from the infamous Star Wars character but these techniques can be used to make almost any helmet. Cody-Helmet-Papercraft.jpg' alt='Star Wars Clone Pepakura Files Download' title='Star Wars Clone Pepakura Files Download' />Once the glue is dry cut out the cheekbone sections on the helmet inner surface. Now make the cheekbone sections by gluing the cheekbone template parts together and bending the cardboard and tacking it into place using a glue gun. I only use the glue gun on the inside of the helmet. Then I smear white glue over all the joints on the outside of the helmet.