How to make a stormtrooper helmet

Written by caroline baldwin
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How to make a stormtrooper helmet
Make a simple "Star Wars" stormtrooper helmet with everyday items. (Getty Creative)

Stormtroopers are iconic "Star Wars" characters. This recognisable figure in intergalactic history has been around since the 1970s. "Star Wars" stormtrooper costumes can be purchased for hundreds of dollars. Forgo the pricey costume for a homemade one this Halloween. Start with making a stormtrooper helmet from a simple, white rubbish bin. The dustbin helmet has an interesting Lego-like hint to the design and is sure to please your "Star Wars" buff.

Skill level:

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Things you need

  • White plastic rubbish bin
  • Ruler
  • All-purpose cleaner
  • Paper towels
  • Protective gloves
  • Lighter
  • 13 mm (1/2") diameter nail
  • Electrical tape
  • Black paper
  • Scissors
  • Double-sided tape
  • Black permanent marker

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  1. 1

    Remove all stickers from the outside of the bin.

  2. 2

    Spray the bin with an all-purpose cleaner and wipe dry with a paper towel. Remove any adhesive and film on the bin so there is a clean exterior surface.

  3. 3

    Turn the rubbish bin upside down on the work surface.

  4. 4

    Mark eye holes on the rubbish bin. Mark a hole 10 cm (4 inches) from the top of the can (as it sits upside down) and 4 cm (1.5 inches) to the right of the centre of the can. Mark another hole 10 cm (4 inches) from the top and 4 cm (1.5 inches) to the left of the centre.

  5. 5

    Put on the protective gloves.

  6. 6

    Hold the nail by the head with the pointed end facing away from your body. Heat the end of the nail with the lighter.

  7. 7

    Heat the nail in the flame for 45 seconds. Place the lighter on the work surface.

  8. 8

    Press the nail to one of the eye hole marks. Firmly push the hot end of the nail into the plastic rubbish bin. The plastic should slightly melt, allowing the nail to pierce through. You may have to do this multiple times to go all of the way through the plastic.

  9. 9

    Repeat the process to create the other eyehole. Remove gloves.

  10. 10

    Cut a piece of black electrical tape. Place the tape about 5 cm (2 inches) from the top of the can. The tape should run from the middle of the left side, across the front, and to the middle of the right side.

  11. 11

    Cut a boomerang-shaped piece of black paper that is about half the width of the can. Place it under the eyes and adhere it to the can with double-sided tape.

  12. 12

    Cut two eye shapes out of black paper. Tape them onto the helmet. Use the cooled nail to punch a hole through the paper to line up with the eye holes.

  13. 13

    Cut a circle 5 cm (2 inches) in diameter circle and two circles 13 mm (1/2 inch) in diameter from the black paper. Stick the 5-cm (2-inch) circle at the bottom centre of the can with tape. Tape the 13-mm (1/2-inch) circles on either side of the larger circle.

  14. 14

    Use the black permanent marker to create shading and vents on the side of the bin.

Tips and warnings

  • Purchase an under-the-desk size white rubbish bin. A square rubbish bin works well. Try the can on your head before purchasing to ensure a good fit.

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