"Star Wars" costumes are always popular at Halloween and costume parties and naturally at "Star Wars" conventions. Making your own helmet is a cheap and easy way to get the look you want without spending a fortune at the costume store and will look just as good. You can decorate the helmet for any "Star Wars" character including bounty hunter Boba Fett from "The Empire Strikes Back." There are numerous online sources for printing out templates for "Star Wars" characters.
Look for Star Wars helmet templates online (see Resources); print one out and glue it to the cardboard with rubber cement. Once the cement has dried cut out the design with a sharp hobby knife. Bend the cardboard to create the bottom of the helmet.
Mist the cardboard with a spray bottle filled with water to make the helmet slightly damp and easier to bend. Epoxy the joint at the back of the helmet and create cheekbone sections by bending the cardboard and using a glue gun on the inside of the helmet to keep it in place. Use white glue on the joints on the helmet's outside.
Make a cardboard ring and glue it to the top of the helmet to keep the dome frame in place. Create the dome by making two interlocking cardboard semicircles and gluing them to the cardboard ring. Cut long triangular cardboard wedges with the knife and bend them as closely as possible to the dome frame.
Glue the wedges to the dome frame with a hot glue gun. Once the dome has been filled use white glue all over the seams on the outside of the helmet. After glue has dried, place the helmet on your head to make sure it fits properly.
Use lightweight spackling paste over the helmet's dome and any other areas that might need smoothing. After the paste has dried use sandpaper to better shape the helmet. Add details and paint as desired; see the References section for ideas.
Use paperboard to create the helmet. Corrugated cardboard will not work. When gluing the cardboard wedges to the dome frame be prepared to do a lot of trimming and adjusting as needed. A few applications of spackling paste are probably necessary to create the exact look you want.
If any glue/paste gets in the eyes, flush immediately with water. Take care when using the hot glue gun not to burn the skin.