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Build time
1 day
Budget
<$100
Skill level
Advanced
Description

Make the Mandalorian’s helmet out of foam and spray paint. The helmet is part of the armor typically warn by the warrior clans on planet Mandalore, and based on Din Djarin’s (aka “Mando”) beskar helmet. According to tradition, Mando could not remove the helmet in front of anyone, otherwise he would not be able to wear it again.

Tools required

• Scissors

• Ball Point Pen

• X-Acto Knife (example here)

• Utility Knife (example here)

• Sandpaper

• Rotary Tool (optional)

• Heat Gun

• Super Glue or Hot Glue Gun

• Small Paint Brush

skills required

• Ability to handle sharp tools

• Safely use a glue gun

• Find a parent if you’re under 13

images for inspiration
No images available
Supply list

Below is a list of all parts used to make this costume. In case you don’t already have them, we’ve included purchase links. Note the estimated cost reflects the cost of a full package (e.g. you may only need 5 screws, but the cost is for a large pack them).

Part Description
Costume section
est. Cost
Part description
4 sheets of “medium” craft foam, 6mm
costume section
Base
Est. Cost
$1.00
Part description
“Thick” foam - garage floor mats, 1/2-inch
costume section
Base
Est. Cost
$9.00
Part description
Barge all-purpose cement
costume section
Base glue
Est. Cost
$9.00
Part description
White caulk
costume section
Base glue
Est. Cost
$4.30
Part description
4 sheets of “thin” craft foam 2mm
costume section
Side pieces & panels
Est. Cost
$1.00
Part description
PVA craft glue (or regular school glue)
costume section
Full coating
Est. Cost
$3.70
Part description
Gray primer
costume section
Paint
Est. Cost
$4.00
Part description
Metallic bronze spray paint
costume section
Paint
Est. Cost
$7.00
Part description
Silver metallic spray paint
costume section
Paint
Est. Cost
$4.00
Part description
Metallic silver acrylic paint
costume section
Paint
Est. Cost
$2.70
Part description
Metallic rich espresso acrylic paint
costume section
Paint
Est. Cost
$5.80
Part description
Brown acrylic paint
costume section
Paint
Est. Cost
$7.00
Part description
Clear gloss spray (optional)
costume section
Paint
Est. Cost
$4.00
Part description
Plastic face shield
costume section
Face shield
Est. Cost
$30.00
Guide

Helmet Base Pieces:

  • Print the templates (100% scale on 8.5x11” paper). Cut them out
  • Trace the templates labelled “MEDIUM” onto the Medium Craft Foam (Be sure to mark the registration marks too.)
  • Cut the pieces out using an X-Acto Knife. 
  • Trace the templates labelled “THICK” onto the Medium Craft Foam 
  • Cut all of the pieces out with a very sharp utility knife (be sure to cut some of the edges with a slight inner or outer angle, refer to the template to see which is which).
  • Flip the templates over and repeat all of the pieces again for the entire right side.

Helmet Base Glue:

  • Use Barge Cement to glue the edge together. Match up the letters to see which piece goes where.
  • I started with the front/face pieces and worked my way back on the sides then across the top.
  • Clean up any spots that need help such as overlapping pieces with the utility knife and/or sandpaper (or a rotary tool if you have one).
  • Fill in any remaining gaps with White Caulk and let dry. 
  • Note: I chose this because it is flexible but it does not sand very well so be sure to wipe it smooth with your finger before it dries.

Side Pieces:

  • Cut out the templates using an X-Acto Knife.
  • Trace the templates twice on either “MEDIUM” or “THIN” craft foam (see templates).
  • Cut the pieces out using an X-Acto Knife. 
  • Stack the pieces as shown and glue with Barge Cement.
  • Smooth out the edges if needed with sandpaper or rotary tool.
  • Glue each side piece onto the helmet with Barge Cement.
  • Cut the light line in Thin Craft Foam as shown with an X-Acto Knife.
  • Use a Heat Gun lightly on these lines to give them more definition.
  • Note: Do not apply the clear coat here! I did it too early, you’ll see when to do it later.

Face Details:

  • Trace the template on “Thin” Craft Foam then flip it over and repeat again for the right side.
  • Cut it out using an X-Acto Knife. 
  • Attach to the helmet with Barge Cement.
  • Trim any excess.
  • Use the Rotary Tool along the curve to create an even angle along the edge.
  • Cut a long, thin strip of “Thin” Craft Foam about 1/4-inch wide and about 9-inches long with the X-Acto Knife.
  • Glue to the helmet using Barge Cement.

Back Panel:

  • Trace the templates on “Thin” Craft Foam.
  • Cut the pieces out out using an X-Acto Knife. 
  • Assemble the pieces on any piece of tape.
  • Attach to the back of the helmet using Super Glue (Hot Glue would also work)

Top Strip:

  • Trace the templates on “Thin” Craft Foam and make it at least 6-inches long.
  • Attach to the helmet with Barge Cement.
  • Trim the excess where it meets the back panel.
  • Cut 2 light lines as shown with an X-Acto Knife using the inner part of the template as a guide. 
  • Use a Heat Gun lightly on these lines to give them more definition.

Full Coating:

  • Coat the entire helmet with PVA Glue and let it dry. If you have time, 2 or 3 coats will make it even smoother.

Paint:

  • Paint the entire helmet with Gray Primer, let dry.
  • Paint the entire helmet with Metallic Bronze Spray Paint, let dry.
  • Lightly (very lightly!) spray some Silver Metallic Spray Paint just to create a slightly shiner and lighter look. Be careful not to do a full coat. Let dry.
  • Paint the side pieces and back a slightly lighter shade using Acrylic Paint.
  • I used a blend of Metallic Silver and Metallic Rich Espresso.
  • Paint the outer edge of the back panel the lightest shade of silver than anything else. The Metallic Silver Acrylic Paint might work on its own but if not try brushing on a bit of the Silver Spray Paint like I did.
  • Lightly coat the entire helmet with very watered-down Brown Acrylic Paint. Make it a little bit heavier near the creases and edges and smudge it with your fingers until it gives everything a greasy, dirty look. Let dry.
  • Spray the entire helmet with Clear Gloss Spray Paint (optional but the shinier the better.)

Face Shield:

  • Trace out a rough template of the shape of the face opening on a scrap paper or piece of craft foam so you’ll know exactly the size and shape of your opening. Draw a new line that’s slightly larger on all sides that will be the shape of the Plastic Face Shield insert.
  • Trace your new template into the Plastic Face Shield.
  • Cut the Plastic Face Shield with a Rotary Tool.
  • Note: If you can find a plastic insert that is not as thick you may be able to cut it out with scissors! Or if you’re just using this helmet as decoration and don’t need to see out of it you could just use a piece of black craft foam.
  • Sand the rough edges.
  • Attach the Plastic Face Shield to the inside of the mask using hot glue.
Guide

Helmet Base Pieces:

  • Print the templates (100% scale on 8.5x11” paper). Cut them out
  • Trace the templates labelled “MEDIUM” onto the Medium Craft Foam (Be sure to mark the registration marks too.)
  • Cut the pieces out using an X-Acto Knife. 
  • Trace the templates labelled “THICK” onto the Medium Craft Foam 
  • Cut all of the pieces out with a very sharp utility knife (be sure to cut some of the edges with a slight inner or outer angle, refer to the template to see which is which).
  • Flip the templates over and repeat all of the pieces again for the entire right side.

Helmet Base Glue:

  • Use Barge Cement to glue the edge together. Match up the letters to see which piece goes where.
  • I started with the front/face pieces and worked my way back on the sides then across the top.
  • Clean up any spots that need help such as overlapping pieces with the utility knife and/or sandpaper (or a rotary tool if you have one).
  • Fill in any remaining gaps with White Caulk and let dry. 
  • Note: I chose this because it is flexible but it does not sand very well so be sure to wipe it smooth with your finger before it dries.

Side Pieces:

  • Cut out the templates using an X-Acto Knife.
  • Trace the templates twice on either “MEDIUM” or “THIN” craft foam (see templates).
  • Cut the pieces out using an X-Acto Knife. 
  • Stack the pieces as shown and glue with Barge Cement.
  • Smooth out the edges if needed with sandpaper or rotary tool.
  • Glue each side piece onto the helmet with Barge Cement.
  • Cut the light line in Thin Craft Foam as shown with an X-Acto Knife.
  • Use a Heat Gun lightly on these lines to give them more definition.
  • Note: Do not apply the clear coat here! I did it too early, you’ll see when to do it later.

Face Details:

  • Trace the template on “Thin” Craft Foam then flip it over and repeat again for the right side.
  • Cut it out using an X-Acto Knife. 
  • Attach to the helmet with Barge Cement.
  • Trim any excess.
  • Use the Rotary Tool along the curve to create an even angle along the edge.
  • Cut a long, thin strip of “Thin” Craft Foam about 1/4-inch wide and about 9-inches long with the X-Acto Knife.
  • Glue to the helmet using Barge Cement.

Back Panel:

  • Trace the templates on “Thin” Craft Foam.
  • Cut the pieces out out using an X-Acto Knife. 
  • Assemble the pieces on any piece of tape.
  • Attach to the back of the helmet using Super Glue (Hot Glue would also work)

Top Strip:

  • Trace the templates on “Thin” Craft Foam and make it at least 6-inches long.
  • Attach to the helmet with Barge Cement.
  • Trim the excess where it meets the back panel.
  • Cut 2 light lines as shown with an X-Acto Knife using the inner part of the template as a guide. 
  • Use a Heat Gun lightly on these lines to give them more definition.

Full Coating:

  • Coat the entire helmet with PVA Glue and let it dry. If you have time, 2 or 3 coats will make it even smoother.

Paint:

  • Paint the entire helmet with Gray Primer, let dry.
  • Paint the entire helmet with Metallic Bronze Spray Paint, let dry.
  • Lightly (very lightly!) spray some Silver Metallic Spray Paint just to create a slightly shiner and lighter look. Be careful not to do a full coat. Let dry.
  • Paint the side pieces and back a slightly lighter shade using Acrylic Paint.
  • I used a blend of Metallic Silver and Metallic Rich Espresso.
  • Paint the outer edge of the back panel the lightest shade of silver than anything else. The Metallic Silver Acrylic Paint might work on its own but if not try brushing on a bit of the Silver Spray Paint like I did.
  • Lightly coat the entire helmet with very watered-down Brown Acrylic Paint. Make it a little bit heavier near the creases and edges and smudge it with your fingers until it gives everything a greasy, dirty look. Let dry.
  • Spray the entire helmet with Clear Gloss Spray Paint (optional but the shinier the better.)

Face Shield:

  • Trace out a rough template of the shape of the face opening on a scrap paper or piece of craft foam so you’ll know exactly the size and shape of your opening. Draw a new line that’s slightly larger on all sides that will be the shape of the Plastic Face Shield insert.
  • Trace your new template into the Plastic Face Shield.
  • Cut the Plastic Face Shield with a Rotary Tool.
  • Note: If you can find a plastic insert that is not as thick you may be able to cut it out with scissors! Or if you’re just using this helmet as decoration and don’t need to see out of it you could just use a piece of black craft foam.
  • Sand the rough edges.
  • Attach the Plastic Face Shield to the inside of the mask using hot glue.
Description

Make the Mandalorian’s helmet out of foam and spray paint. The helmet is part of the armor typically warn by the warrior clans on planet Mandalore, and based on Din Djarin’s (aka “Mando”) beskar helmet. According to tradition, Mando could not remove the helmet in front of anyone, otherwise he would not be able to wear it again.

Tools required

• Scissors

• Ball Point Pen

• X-Acto Knife (example here)

• Utility Knife (example here)

• Sandpaper

• Rotary Tool (optional)

• Heat Gun

• Super Glue or Hot Glue Gun

• Small Paint Brush

skills required

• Ability to handle sharp tools

• Safely use a glue gun

• Find a parent if you’re under 13

images for inspiration
No images available
Supply list

Below is a list of all parts used to make this costume. In case you don’t already have them, we’ve included purchase links. Note the estimated cost reflects the cost of a full package (e.g. you may only need 5 screws, but the cost is for a large pack them).

Part Description
Costume section
est. Cost
Part description
4 sheets of “medium” craft foam, 6mm
costume section
Base
Est. Cost
$1.00
Part description
“Thick” foam - garage floor mats, 1/2-inch
costume section
Base
Est. Cost
$9.00
Part description
Barge all-purpose cement
costume section
Base glue
Est. Cost
$9.00
Part description
White caulk
costume section
Base glue
Est. Cost
$4.30
Part description
4 sheets of “thin” craft foam 2mm
costume section
Side pieces & panels
Est. Cost
$1.00
Part description
PVA craft glue (or regular school glue)
costume section
Full coating
Est. Cost
$3.70
Part description
Gray primer
costume section
Paint
Est. Cost
$4.00
Part description
Metallic bronze spray paint
costume section
Paint
Est. Cost
$7.00
Part description
Silver metallic spray paint
costume section
Paint
Est. Cost
$4.00
Part description
Metallic silver acrylic paint
costume section
Paint
Est. Cost
$2.70
Part description
Metallic rich espresso acrylic paint
costume section
Paint
Est. Cost
$5.80
Part description
Brown acrylic paint
costume section
Paint
Est. Cost
$7.00
Part description
Clear gloss spray (optional)
costume section
Paint
Est. Cost
$4.00
Part description
Plastic face shield
costume section
Face shield
Est. Cost
$30.00
Guide

Helmet Base Pieces:

  • Print the templates (100% scale on 8.5x11” paper). Cut them out
  • Trace the templates labelled “MEDIUM” onto the Medium Craft Foam (Be sure to mark the registration marks too.)
  • Cut the pieces out using an X-Acto Knife. 
  • Trace the templates labelled “THICK” onto the Medium Craft Foam 
  • Cut all of the pieces out with a very sharp utility knife (be sure to cut some of the edges with a slight inner or outer angle, refer to the template to see which is which).
  • Flip the templates over and repeat all of the pieces again for the entire right side.

Helmet Base Glue:

  • Use Barge Cement to glue the edge together. Match up the letters to see which piece goes where.
  • I started with the front/face pieces and worked my way back on the sides then across the top.
  • Clean up any spots that need help such as overlapping pieces with the utility knife and/or sandpaper (or a rotary tool if you have one).
  • Fill in any remaining gaps with White Caulk and let dry. 
  • Note: I chose this because it is flexible but it does not sand very well so be sure to wipe it smooth with your finger before it dries.

Side Pieces:

  • Cut out the templates using an X-Acto Knife.
  • Trace the templates twice on either “MEDIUM” or “THIN” craft foam (see templates).
  • Cut the pieces out using an X-Acto Knife. 
  • Stack the pieces as shown and glue with Barge Cement.
  • Smooth out the edges if needed with sandpaper or rotary tool.
  • Glue each side piece onto the helmet with Barge Cement.
  • Cut the light line in Thin Craft Foam as shown with an X-Acto Knife.
  • Use a Heat Gun lightly on these lines to give them more definition.
  • Note: Do not apply the clear coat here! I did it too early, you’ll see when to do it later.

Face Details:

  • Trace the template on “Thin” Craft Foam then flip it over and repeat again for the right side.
  • Cut it out using an X-Acto Knife. 
  • Attach to the helmet with Barge Cement.
  • Trim any excess.
  • Use the Rotary Tool along the curve to create an even angle along the edge.
  • Cut a long, thin strip of “Thin” Craft Foam about 1/4-inch wide and about 9-inches long with the X-Acto Knife.
  • Glue to the helmet using Barge Cement.

Back Panel:

  • Trace the templates on “Thin” Craft Foam.
  • Cut the pieces out out using an X-Acto Knife. 
  • Assemble the pieces on any piece of tape.
  • Attach to the back of the helmet using Super Glue (Hot Glue would also work)

Top Strip:

  • Trace the templates on “Thin” Craft Foam and make it at least 6-inches long.
  • Attach to the helmet with Barge Cement.
  • Trim the excess where it meets the back panel.
  • Cut 2 light lines as shown with an X-Acto Knife using the inner part of the template as a guide. 
  • Use a Heat Gun lightly on these lines to give them more definition.

Full Coating:

  • Coat the entire helmet with PVA Glue and let it dry. If you have time, 2 or 3 coats will make it even smoother.

Paint:

  • Paint the entire helmet with Gray Primer, let dry.
  • Paint the entire helmet with Metallic Bronze Spray Paint, let dry.
  • Lightly (very lightly!) spray some Silver Metallic Spray Paint just to create a slightly shiner and lighter look. Be careful not to do a full coat. Let dry.
  • Paint the side pieces and back a slightly lighter shade using Acrylic Paint.
  • I used a blend of Metallic Silver and Metallic Rich Espresso.
  • Paint the outer edge of the back panel the lightest shade of silver than anything else. The Metallic Silver Acrylic Paint might work on its own but if not try brushing on a bit of the Silver Spray Paint like I did.
  • Lightly coat the entire helmet with very watered-down Brown Acrylic Paint. Make it a little bit heavier near the creases and edges and smudge it with your fingers until it gives everything a greasy, dirty look. Let dry.
  • Spray the entire helmet with Clear Gloss Spray Paint (optional but the shinier the better.)

Face Shield:

  • Trace out a rough template of the shape of the face opening on a scrap paper or piece of craft foam so you’ll know exactly the size and shape of your opening. Draw a new line that’s slightly larger on all sides that will be the shape of the Plastic Face Shield insert.
  • Trace your new template into the Plastic Face Shield.
  • Cut the Plastic Face Shield with a Rotary Tool.
  • Note: If you can find a plastic insert that is not as thick you may be able to cut it out with scissors! Or if you’re just using this helmet as decoration and don’t need to see out of it you could just use a piece of black craft foam.
  • Sand the rough edges.
  • Attach the Plastic Face Shield to the inside of the mask using hot glue.
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