How to Make a Clone Trooper Helmet Out of Paper

Whether you're getting ready for Halloween or the next Star Wars convention, having the right costume is essential. However, these costumes are expensive if you crave attention to detail and an accurate reproduction. Thankfully, you can make your own clone trooper helmet at home using paper in the form of paper mache. With some time and effort, you'll have a completed helmet that's the talk or your next Star Wars event.

Blow a large balloon up a few inches larger than your head. Mark out the location of your eyes, the centre top of your head and the lowest point of your chin.

Cut out squares of poster board and tape to the surface of the balloon in the basic shape of the clone trooper helmet. Don't be concerned with details as this will act as an armature of the final helmet. Make sure that the distance between the bottom of the helmet to the top is equal to the distance from the top of your head to the top of your shoulders.

In a mixing bowl, combine white flour with water. Add the water slowly as you mix until you have a thin paste. Dip your paper strips into the mix and apply to the helmet armature. Use reference images as you apply the paper strips covering the balloon and poster board pieces. Build up the clone trooper helmet shape as you build up the layers. You should have about five layers of paper to make a sturdy helmet.

Let the wet paper strips dry to the touch for a few hours. Flip the helmet over and remove the poster board and pop the balloon, removing it as well. Allow the helmet to completely dry inside and out in a dry area or in the sun. This may take a day depending on the thickness of the layers.

Paint the helmet using reference images. First paint the entire helmet white as your base colour, then apply black and grey for the visor and mouth details. With a sharp craft knife, cut slots on the mouth details to add ventilation for breathing.

Things You'll Need

  • Balloon
  • Poster board
  • Flour
  • Water
  • Paper strips
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About the Author

Brenda Barron is a writer, editor and researcher based in Southern California. She has worked as a writer since 2004, with work appearing in online and print publications such as BabyZone, "Cat Fancy" and "ePregnancy." She holds a Bachelor of Arts in English literature from California State University, Long Beach.