How to make a Darth Vader mask from a cardboard box

Updated April 17, 2017

Making a Darth Vader mask from a cardboard box can be a fairly easy task. Darth Vader, one of the world's best-known film villains, is a key figure of the "Star Wars" film and the Dark Lord of the Sith. Old black boots and black clothing can be worn to accompany the mask to give a full Darth Vader effect. The Darth Vader mask can be worn to costume parties.

Find a picture of the Darth Vader mask you'd like to duplicate. Print it out for reference. Depending on the size of the box, you may make an adult-sized Darth Vader mask or a child-sized Darth Vader mask. Use a square box to make the mask. An 45 x 60 cm (18 inch by 24 inch) box will do.

Purchase about a litre (1 quart) of black paint from a local hardware shop. This will be for the box. The amount of paint needed depends on the size of the cardboard box, but you should need no more than a litre (1 quart).

Cut holes in the cardboard box where the eyes should go. You can fill in the eye holes with tinted sunglasses lenses; cut the eye holes in the exact shape of the sunglasses lenses. Trace the outline of the lenses before cutting the holes. The tint on the sunglasses lenses should be as dark as possible. Put super glue around the edges of the eye holes and carefully put the sunglasses lenses into the holes.

Use scissors to cut slits in a space below the nose area on the box. The slits should be about a 6 mm (1/4 inch) apart. The mouth slits should be cut into the shape of a triangle. Cut off the front flap of the box so that the rest of the box can rest gently on your shoulders.

Paint the box black except for the mouth area. Paint the mouth area where the slits are a grey or silver colour. Add a few silver or grey gems around the mouth area. Let the paint dry for at least a day before putting the mask on.


To complete the costume, you could dress in all black and buy a small black cape. Add a light sabre and black leather gloves from an old wardrobe box or you can buy new ones. Get ideas from the actual Darth Vader costume on how to make the costume complete.

Things You'll Need

  • Cardboard
  • Black paint
  • Grey or silver paint
  • Scissors
  • Sunglasses lenses
  • Glue
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About the Author

Shaleah Patterson has been writing since 2001. Whether it was non-fiction novels in composition notebooks or poems, songs and newspaper articles, Shaleah has always had a passion for writing. Patterson's work has appeared in various online publications. She has attended Dutchess Community College, and is currently attending Jefferson Community College.