The form is made from templates pages 4, 8, 11 and 12. This is used to help establish the basic helmet shape and is later removed from the helmet. The first step is to make the form for the helmet base. I then glued them to the cardboard with some rubber cement and then cut out all the pieces with an X-Acto knife.

The best way to work with the templates is to cut them out and tape the separate sheets together. 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. I was able to download some Fett helmet templates from the Dented Helmet forum. For this example I'm going to construct a Boba Fett helmet from the infamous Star Wars character but these techniques can be used to make almost any helmet. You'll also need some white glue, sandpaper, a hot glue gun, some, an X-Acto knife and some. Crescent shows it on their website as Grey News Mounting Board: Some people have reported that also works extremely well. It is manufactured by Crescent as well as Arches and is sold at craft and picture framing stores. The kind I used is called newspaper board and it comes in 30'x40' sheets. Use the kind that looks like paperboard- corrugated cardboard won't work. For more great scifi costuming templates check out -there's a lot of fantastic patterns there! You'll need some cardboard sheet- about 1/16 inch thick material works best. The methods I describe can be used to make almost any kind of helmet but I'm showing how to make a Star Wars Boba Fett helmet as an example - I have an instructable for the rest of the Boba Fett costume here: The templates provided are used by permission from The Wizard of Flight via the Dented Helmet- the definitive resource-thanks Alan! The templates are designed to be printed on 8.5' x 11' paper.

Helmets are usually one of the hardest and most expensive parts to make for a cool Halloween costume so here's a simple method I use. Here's how to make a low cost costume helmet using cardboard. But i cant find ay templates! Bleahhh, #3 (You must log in or sign up to reply here.) Show Ignored Content. I already have a starfortress bucket so that part is settled. I really would like to make a CT phase 1 out of foam.

Heatshock: thanks for the info~ but at this point of time, i am low on budget.

Pepakura simple helmet pattern foam