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. You have to wear safety glasses when using Cyanoacrylate adhesive, because it's very much liquid and dangerous and can injure your eyes if not careful.Heatshock: thanks for the info~ but at this point of time, i am low on budget. I use 2 mm EVA foam for the material, using UHU and Cyanoacrylate adhesive (super glue). This is the 3d file that already edited in first attempt, the final 3d is a bit different with this. This pep file scale is set to 1 (1:1 scale), the complete helmet is 27 cm / 10.6 inches in height (my size), if you want make it bigger change the scale with 1.1 if you want to have 110% size or 1.05 for 105%. I even create a photo album for this project in my Facebook as you can see the photos below. Then I edit the file by reducing 3d segments, replace some parts with new parts, and edit the 3d a bit to be use as a template that specially setup for foam material. I want to use EVA foam for the helmet and rest of the armor material because it's cheap, very easy to cut and bend and also very lightweight. The original pep was unfolded solely for making resin helmet master purpose, so the segments are too many to be made by using foam. It is ANH Hero TK helmet pepakura file unfolded by Fierfek. So I began searching for the existing pepakura template on RPF.com and found one that in my opinion is quite detail and accurate. I started with the most difficult part, the helmet. I decided to make a full armor costume of Sandtrooper, I think this imperial unit is really cool, with all the stuff in his backpack and a big gun. I was a bit boring with paper model so I decided to refresh my mood for a while.

Pepakura simple helmet pattern foam