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  1. practicecactus's Avatar
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    Mar 3, 2013, 7:30 PM - Oversized 1:1.5 Darth Vader helmet. #1

    Hope you enjoy the reprieve from all the Mass Effect 3 guns and Iron Man builds ;P.

    This is my cardboard oversized Darth Vader helmet. At 1:1.5 scale, made entirely out of cardboard and wood glue so far.
    I had started a previous version, some of you may have seen in a thread quite a while back, and while I got pretty far with it, it sat for a long time and coming back to it one day to try to finish it off, I realized how incredibly cringe-worthy it was looking, so I decided to start again from scratch.

    Using my Rubies Vader helmet, I made pattern-templates off it to upscale it. I know the Rubies bucket is far from perfect so I tried to learn as much as I could from photos. I need to thank starwarshelmets.com and everyone who's made Vader helmets, for all the photo references.

    The plan is to resin it up and body-filler it as well as I can, then paint it up, so I'm making a note of all the areas that need fixing at this stage. If you've got any advice on areas that need work [so long it's not completely unfixable at this stage] I'm totally open to constructive criticism. I'm really pushing myself on the accuracy because while I know I'll never get it to 100%, at least I can try to get it as perfect as I can and hopefully still do an ok job overall. The dome of the helmet is really hard to do without any right angles or hard edged starting points. Even taking measurements as much as I can, in some places on the helmet I'm still off by about 10 to 20mm. Also if anyone has any tips on resin with cardboard, I'd love to hear from you. I used to work with fiberglass but never used it on cardboard, but I'm assuming the resin will soak into the cardboard pretty well but should I also glass up the inside of the dome and weight stress areas, or will it hold together ok? Being cardboard itís super light at the moment, so Iím not sure how the added weight of resin will work out.

    I do hope to one day get the rest of the costume together and wear it to a con, so the idea is completely silly, but I'm playing it straight. I'm treating this like a proper replica helmet build. Just a little bigger.

    Couldnít tell you how many hours Iíve spent on this thing. Iíve just slowly been chipping away at it late at night, small pieces at a time. Total money spent on it so far has pretty much just been on about 5 rolls of masking tape, so about 10 bucks so far, I guess.

    No plans to make copies of it when itís finished. I think Iíd have to make a vacuum forming rig and split the helmet down the middle to do that. But I might make a vacuum forming table to make a plastic version once I have all the surface prep done. Weíll see when I come to that.

    I just really wanted a big Darth Vader helmet and one didnít exist.

    [Apologies in advance for Instagram versions of some of the photos]













    It's at this point I realised I shouldn't be using masking tape to hold it together and should just glue everything together. I don't know why I thought masking tape was a good idea. I also don't know why I made the chin grill opening with hard corners. I totally forgot to make the corners rounded.


    Reinforcing the neckline so it keeps it's shape. Naked thigh for free.
















    Making pattern of the helmet's skirt.










    Checking placement look.


    Photo taken further back.








    Adding extra layer inside to hold it's shape and proper distance.




    Reinforcing for the helmet attachment.


    I don't know what I saw in my previous attempt.




    So that's where I'm at so far. I still need to work on the attachment system for the helmet to the mask. Might leave it for a few days so I can notice any mistakes when I come back to it fresh, but I'm sure you Vader experts can point out anything that's not looking right. I'll have to take some better pics at the correct distance. You guys insist on photos taken 6 feet back for helmets right? I guess I'll have take my photos from 9 feet back.
    I've tried to incorporate any asymetrical mistakes in the original, but realise I may not be able to what with the limitations of cardboard, but I am gonna at least try.
    Last edited by practicecactus; Oct 28, 2013 at 8:07 AM.
  2. Member Since
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    Mar 3, 2013, 8:20 PM - Re: Oversized 1:1.5 Darth Vader helmet. #2

    That's pretty awesome for a cardboard build.
  3. Member Since
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    Mar 3, 2013, 8:23 PM - Re: Oversized 1:1.5 Darth Vader helmet. #3

    Very very impressive for using just cardboard.
  4. laserpistol76's Avatar
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    Mar 3, 2013, 8:30 PM - Re: Oversized 1:1.5 Darth Vader helmet. #4

    TK9120 said: View Post
    That's pretty awesome for a cardboard build.
    This is amazing!
  5. RPF Premium Member manooga's Avatar
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    Mar 3, 2013, 8:40 PM - Re: Oversized 1:1.5 Darth Vader helmet. #5

    Wow, you've got skills dude! Congrats! amazing work there.
  6. jme3's Avatar
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    Mar 3, 2013, 8:59 PM - Re: Oversized 1:1.5 Darth Vader helmet. #6

    Wow, what a huge Vader...!
  7. xsaenz's Avatar
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    Mar 3, 2013, 9:04 PM - Re: Oversized 1:1.5 Darth Vader helmet. #7

    That's really good, I want one!
  8. Chara limit is way too sm RPF Premium Member Nwerke's Avatar
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    Mar 3, 2013, 9:17 PM - Re: Oversized 1:1.5 Darth Vader helmet. #8

    I think you win the Most Eccentric Build of the Week award for sure.

    ...it's great! More!
  9. Universal Greeblie RPF Premium Member Jedifyfe's Avatar
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    Mar 3, 2013, 9:34 PM - Re: Oversized 1:1.5 Darth Vader helmet. #9

    So, what's this for? Pretty damn cool!
  10. practicecactus's Avatar
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    Mar 3, 2013, 10:16 PM - Re: Oversized 1:1.5 Darth Vader helmet. #10

    Cheers for the kind words guys.
    And what's it for Jedifyfe? Just for fun.
  11. RPF Premium Member manooga's Avatar
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    Mar 3, 2013, 10:24 PM - Re: Oversized 1:1.5 Darth Vader helmet. #11

    practicecactus said: View Post
    Cheers for the kind words guys.
    And what's it for Jedifyfe? Just for fun.
    You could build Darth Vader piŮatas and sell them!!
  12. RPF Premium Member cavx's Avatar
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    Mar 4, 2013, 2:52 AM - Re: Oversized 1:1.5 Darth Vader helmet. #12

    Awesome work. Who thought card board and tape could be so versatile?

    Sorry for asking, why 1.5x?
  13. Member Since
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    Mar 4, 2013, 3:05 AM - Re: Oversized 1:1.5 Darth Vader helmet. #13

    That looks pretty cool, well done mate
  14. RPF Premium Member Blaxmyth's Avatar
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    Mar 4, 2013, 3:42 AM - Re: Oversized 1:1.5 Darth Vader helmet. #14

    The thread title intrigued me, and the photos hooked me totally. Subscribed!

    Loving every aspect of this build!
  15. Pobbrett's Avatar
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    Mar 4, 2013, 5:01 AM - Re: Oversized 1:1.5 Darth Vader helmet. #15

    yay Darth Vader bobble head costume awesome.

    I've seen a few card board builds and always wondered why people have used the old paper mache over a balloon for the dome i've used it for viking helmets for the kids school projects, just make a head band to the size you want and inflate the balloon inside it then go at it with the glue and newspaper although i don't know if it would react well with resin.

    keep up the great work.
  16. SofaKing01's Avatar
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    Mar 4, 2013, 7:57 AM - Re: Oversized 1:1.5 Darth Vader helmet. #16

    WOW!!! You know you can't stop at just the helmet... Great work so far!
  17. gunnerk19's Avatar
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    Mar 4, 2013, 12:35 PM - Re: Oversized 1:1.5 Darth Vader helmet. #17



    Woah, Darth Venom!
  18. practicecactus's Avatar
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    Mar 4, 2013, 12:46 PM - Re: Oversized 1:1.5 Darth Vader helmet. #18

    cavx said: View Post
    Sorry for asking, why 1.5x?
    Well, I orginally just wanted something star wars, really big. I was looking into modifying my Rubies Vader helmet at the time and saw a couple of Bobblehead Vader toys, and then there's Spaceballs.. it all just kinda clicked in my head. 1.5 is the perfect size to work with. 2x would just be too big to get through a doorway.

    Pobbrett said: View Post
    I've seen a few card board builds and always wondered why people have used the old paper mache over a balloon for the dome i've used it for viking helmets for the kids school projects, just make a head band to the size you want and inflate the balloon inside it then go at it with the glue and newspaper..
    I didn't even think to do it that way.
    Well, this way does afford me to get the angles right. I'm now pretty good at knowing how much of a slit to take out of cardboard to curve it, and although yeah, you could totally start from a sphere shape and add the angles to it, I went the other way and saw it more as a box with curves.

    SofaKing01 said: View Post
    .. You know you can't stop at just the helmet...
    Heh, no, no. That would just be too massive an undertaking. If I get the rest of the costume together, I think just the gloves would be oversized too.

    Thanks again for encouragement guys.
  19. Jsimon999's Avatar
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    Mar 5, 2013, 5:15 AM - Re: Oversized 1:1.5 Darth Vader helmet. #19

    People just never cease to amaze me here.


    Jon
  20. biguk's Avatar
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    Mar 5, 2013, 7:29 AM - Re: Oversized 1:1.5 Darth Vader helmet. #20

    The creativity in this is awesome. Are you going to leave the cardboard bare or cover it up?
  21. Plaster surgeon RPF Premium Member animefan's Avatar
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    Mar 5, 2013, 6:47 PM - Re: Oversized 1:1.5 Darth Vader helmet. #21

    wow that has turned out impressive so far.
  22. Wes R is offline Wes R
    Formerly cobalt crimson
    Mar 5, 2013, 8:56 PM - Re: Oversized 1:1.5 Darth Vader helmet. #22

    practicecactus said: View Post
    Cheers for the kind words guys.
    And what's it for Jedifyfe? Just for fun.
    You could go costuming as a Vader Bobble-head with that mask on over a normal costume.
  23. practicecactus's Avatar
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    Mar 5, 2013, 10:15 PM - Re: Oversized 1:1.5 Darth Vader helmet. #23

    You kid, but I thought about it, albeit for all of about 3 seconds before I remembered how uncomfortable and hot a Vader helmet gets. It doesn't quite fit anyway, but almost.

    At the moment I'm working on getting a head strap inside. I was gonna use one of those real nice lookin hard hat suspension webbing liners people use for Storm Trooper helmets but there's no real way to fix it to the inside of my thing. So I'm just gonna use an on old welding mask one because it's got those two handy screw points on the sides. Planning on making a few holes so I can choose and adjust it, if shoulder armour should get in the way. Then it's onto attaching the helmet to the mask, which is gonna be tricky to set up and check it's placement but I've noticed Vader helmet helmet-to-mask angles vary.
  24. RPF Premium Member Cenobyte's Avatar
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    Mar 5, 2013, 10:20 PM - Re: Oversized 1:1.5 Darth Vader helmet. #24

    You all amaze me what you can do with paper and cardboard. I am good, but to do a 1:1.5 scale is awesome.
  25. gizmo's Avatar
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    Mar 6, 2013, 3:15 AM - Re: Oversized 1:1.5 Darth Vader helmet. #25

    You sir are seriously impressive!!!


    Ben

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