DIY Cosplay Helmet

My 4-year-old is bonkers for all things super heroes and Star Wars so I decided to make him a Boba Fett helmet out of the stack of spare floor mats we had when he was crawling around as a baby. It was my first time making anything cosplay related and I learned a lot in the process.

There’s a lot of scattered tutorials out there for very specific outcomes but I thought it would be helpful to share a simple, high-level guide on how to approach a project like this so you know what’s involved in the larger journey before committing yourself to the details. I’ve broken this project down into three main phases:

  1. Design the Pattern
  2. Construct the Form
  3. Paint and Surface

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