While my kids were here for the summer I got a wild hair and decided to try my hand at making my sons posterboard Fett helmets. While searching for a formula for making the dome I found this site, and my life's been in shambles ever since!
When we went to the MoM show up in Huntsville my oldest wanted one of the Jango costumes that had at the gift shop. I got it for him but he was disappointed in it to say the least. I set out to build him a decent helmet and am now neck deep in two full costumes!
I took a guess at what size helmet I'd need and went to work on a Jango helmet. My intent was to use posterboard and impregnate it with resin. I ended up using glass sheet as well. In the end I added styrene for the outer layer and it worked out well. However, I won't go the resin impregnated route again after seeing how easily knee armor and cod pieces done the same way came apart.
When I got to the cheeks I got worried the helmet may be too small. My son's several states away, so no way to try it on. About that time my youngest announced he wanted to go as Boba, so the Jango helmet became a Boba.
Again, not being sure what size to make the helmet I had to guess. Hearing some adults find the WOF helmet templates a bit small I figured it best and easiest, due to computer/printer issues, to use them full sized. Plus it'd give him room to grow into it.
The second helmet I made strictly out of sheet styrene and fiberglass. The templates used to form the dome and bucket were cardboard, so there's a strip here and there deep under the fiberglass.
Anyway, this is my progress so far. By an odd twist of events I'll get to see the boys briefly this week, giving me a chance to see if the helmets and single gauntlet I've built so far will fit.