How to Make a Plastic Mandalorian Helmet

Measure the distance between the corners of the open face of the BMX helmet. Add 1 inch to this measurement and make a note of it. Measure the distance between the bottom of the forehead part of the helmet to the bottom of your chin. Draw a rectangle on the stiff plastic sheet using those two measurements. Cut this rectangle out with a craft knife.

Measure halfway along one of the longest sides of the rectangle and make a mark at the halfway point. Measure 1/2 inch on either side of the mark, making another mark at each point, and cut a 1 inch long, ¼-inch deep notch in the top of the rectangle. Mandalorian helmets often have notches just below the eye area across the bridge of the nose as part of their design.

Line the rectangle up against the open face part of the helmet. The two edges of the rectangle should be overlapping by 1/2 inch onto the part of the helmet that covers the ears. The notch should be at the top of the rectangle and should be in the dead center of the face. Drill through the two top corners of the rectangle into the ear area of the BMX helmet. Push a small plastic screw through the hole and secure with a plastic bolt. Trim the screw with the bolt cutters and cover with foam to prevent it injuring the wearer's head. Drill through the other corner of the rectangle into the ear area on the other side of the helmet as well. This creates a hinge, allowing the rectangle to cover the bottom half of the face but be pulled down slightly to create an opening around the eye area so the wearer can see.

Rub all the plastic surfaces with a scouring pad to roughen them prior to painting. Run the blowtorch lightly over the surface and wipe down with alcohol spray to allow the paint to stick to the plastic. Spray the whole helmet with a base coat of primer. Then spray the whole helmet your chosen basic color.

Measure the distance from the edge of the plastic rectangle to the notch in the middle of the rectangle. Then measure from the corner of this notch to the bottom of the rectangle. Draw an "L" shape on the same sheet of plastic that you cut the rectangle from. At the edges of the "L" shape begin drawing a parallel line about a 1/4 inch inside the initial line. Continue drawing these parallel lines until you are 1 inch away from the right-angle of the "L" shape. Join these two secondary lines with a sweeping curve that bends toward the apex of the corner. You should be left with a thickened "L" shape with a smooth corner on the inside and an sharp angle on the outside.

Draw a mirror image of this "L" on the plastic also and cut both shapes out with the craft knife. Prep the two shapes with the blow torch and alcohol and paint them a contrasting color to the rest of the helmet. Line the outside corner of one of "L" shapes up with the notch on the plastic rectangle and glue the "L" shape into place. Because of the curve of the plastic you will need to hold it till the glue dries. Repeat this with the other "L" on the other cheek. Check the picture in the reference section while carrying out this step.