AntMan's Second Cardboard Scratch Build


Just to relight the fire on this one guys it stops after the sanding of the filler. what are the next steps afterwards? Is there any fibreglass of filler that needs to go on the faceplate or is it straight to priming?

Any exposed paper/cardboard you'll want to petrify, yeah. Otherwise you'll be sanding raw cardboard, which is about the least sandable material in the world. Pretty much anything that soaks some into the cardboard and hardens will work, but yeah, fiberglass resin (without the matting) is a popular option.

So yeah, petrify any exposed cardboard, then get it as smooth as you can via sanding and filler, then start priming. The initial priming layer will mostly just be another filler coat layer, for any tiny little scatches and such, so thick filler/sandable primers work best (I'm a big fan of Rustoleum '2 in 1 Filler and Sandable Primer').

Layering, sanding, then layering again is gonna be a long process that takes up the majority of the time of any scratch build, but putting the elbow grease into it makes all the difference between a good clean build and a lumpy one.


New Hunter
I have mixed feelings dredging up this old thread. AntMan If you are by any chance reading this I came across this build back when I was in high school and followed it in amazement. I set out to do it myself. I got the whole cardboard bucket built but when it came to filler and sanding I just lacked the skill. Now I'm 25 and I'm back at it again. I look forward to finishing this time!


I've been making my own props since 1996 when I made my first scratch built Vader for Halloween (wasn't pretty!)
Keep at it and eventually you'll learn enough to get pretty good at it. EVERY single prop, helmet, gun you make just gives me more experience for the next one. Keep at it and don't give up!


This is awesome. I'm working on some gauntlets this week and next for my son's Halloween costume and the helmet is that last on the list. Going to definitely doing it this way and hopefully bang it out in a couple of weeks


New Hunter
you do make it look easy.

I'm at the ear part myself.
the pdf I'm using were old and seem to have been printed out at slightly the wrong size so it's been a challenge. it's nice to sed how it's supposed to be done . Haha