Star Wars TFA stormtrooper helmet build


New Member
Hello all.

I decided to start a stormtrooper helmet build that will hopefully be completed by the release of the movie in December. I am not an experienced prop maker I have only tried out pepakura building so any suggestions would be welcome.
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Early paper stage with a little bondo work on the nose piece and the top.

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Most recent progress. Any suggestions for getting the small details carved out under the nose piece and around the eyes?


New Member
Hello all. It's been a while since I have been able to work on my helmet due to work. I'm back at it though, and only a little over a week until the movie comes out. Guess that means it's crunch time!

Here are some updates to the helmet over the past week.
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Used some thin foam sheets with sticky backing before I put on some bondo to create the strip on the sides and the back. I'm at the point where I can finally add in some details and start smoothing things out. Let me know what you guys think!

P.S. Does anyone know where I can get some black hexagonal mesh for the mouth? I want to cut out what I have and put some mesh with a hexagon pattern and maybe some black cloth behind it so you can't see through.


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New Member
Hey guys a bit of an update on my stormtrooper helmet. Got a lot done this last week. The mouth piece is now cut out and i intend on replacing it with some kind of hexagonal mesh. Also did a ton more sanding. If anyone has any info on where I can find some kind of rubber or plastic hexagonal mesh, please share with me! I can't find anything other than places that require a minimum order of 100+ rolls of this material.

Here are a few new progress photos.

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