Han and Lucasfilm's son is known as BenSolo.He aspires to be like Darth Vader.His costume is similar to Darth Vader's, with a red lightsaber and intimidating mask.It is possible to make your own mask for less than you would pay for a replica online.
Step 1: A plastic dome is large enough to fit on your head.
A small, plastic trashcan with a domed lid will work the best if the lid is taken off.There is a plastic bowl with a rounded top.It will look clunky if the dome has a similar circumference to the one on your head.The dome's rim should be above your ears.If you use a plastic trashcan lid, make sure the lid is secured from the inside with black duct tape.
Step 2: Take your neck guard measurements after putting the dome on.
You can measure around the dome's rim from your left temple to your right temple.Measure from the dome's rim to your jaw.
Step 3: Cut a piece of plastic from your body.
If you are using a plastic trashcan, you should cut this rectangle from the can part.A sheet of thin plastic or craft foam can be used.Posters can be used, but keep in mind that your helmet won't be very durable.Don't use the trashcan dome or plastic bowl for this.The helmet has a dome on top.There is a neck guard.Most plastics can be cut with a craft blade or scissors.If the craft blade is old, it won't be sharp enough.
Step 4: Attach the neck guard to the rim.
If you want something more durable, use an industrial strength glue such as E6000 instead of hot glue.Before moving on, let the glue set.The front part of the flap should be in the domed trashcan lid.The width of your forehead needs to be spanned by the opening between the 2 vertical edges of the neck guard.Before you glue, test the fit and trim it.
Step 5: To make the rim, trace the bottom of the neck guard onto cardboard.
Place your helmet on a piece of cardboard.To make a C-shape, trace the bottom edge of the neck guard.Take the helmet away and trace 2 inches outside the C-shape.You'll have a C-shape that is 2 inches thick when you're done.The rim on the bottom part of the neck guard will be created by this.You can use foam, plastic or poster board.The C-shape should be shorter on each side than on the neck guard.
Step 6: Attach the C-shape to the neck guard.
Put your C-shape against the base of the neck guard.The inside curve of the C-shape should be secured with hot glue or industrial strength glue.Before moving on, let the glue set.The vertical side edges of your neck guard should be at least 1 inch from the ends of the C-shape.If needed, trim the ends of the C-shape.
Step 7: The outline of Kylo's mouth is on the edge of the neck guard.
The shape begins at the top right corner, where the neck guard touches the dome's rim.It curves down towards the bottom edge of the neck guard.The shape of the neck guard should be reversed.You can see the lines with a white chalk or marker if you are using black or dark plastic.There are reference photos of Kylo Ren's helmet.If you can, copy the side edge of his mouthguard.
Step 8: Cut a skinny piece of plastic.
You used the same material for the neck guard.It needs to be the same length as the neck guard, but half the height.The neck guard on the helmet doesn't just point straight down.It is kind of like a samurai helmet.
Step 9: Cut the curved lines onto the skinny rectangle.
The neck guard should be placed against the skinny rectangle.The skinny rectangle has curved lines from the neck guard.The skinny rectangle has curved lines on it.Don't cut the curved lines on the neck guard, you need that excess material to secure it.
Step 10: The neck guard and base should be Glued to.
The neck guard should be touching the top edge of the skinny rectangle.The inside edge of your cardboard C-shape should be touching the bottom of the skinny rectangle.Glue these down first, then glue the skinny rectangle to the neck guard.
Step 11: Make a template out of tracing paper.
Attach a piece of tracing paper to your helmet.Take the curved lines that you drew on your neck guard and put them on the paper.The paper should be cut along the lines.The paper needs to be the same height as the neck guard.
Step 12: Look at the placement of your eyes and nose.
Make sure the curved edges of the paper template match the lines on the neck guard by taping it to the front of your helmet.Feel the bridge of your nose and eye sockets when you put the helmet on.To mark these lightly, use a pen or pencil.
Step 13: Cut out the eye holes from the paper.
There are reference pictures of the mask from the front.The mask's eyes are rectangular but narrower in the middle.If you want to use your eye and nose bridge markings as a guide, take the paper off first, then copy this shape as best as you can onto your template.The eye holes can be cut with scissors or a craft blade.
Step 14: Attach the template to black craft foam.
Attach your paper template to the black foam.The template should be traced onto the foam.Then trace the other half of the template.You traced the lines.To see the template, use a white pen to trace it.The base of the template can be cut with scissors, but you should use a craft blade for the eye holes.
Step 15: Glue the base to the helmet.
Make sure that the curved side edges match the lines that you drew on the neck guard.The best glue for this step is an industrial strength.
Step 16: The template has silver details on it.
There are more reference pictures of the mask.Attach the silver lines on his mask to the tracing paper template.You can fill in the negative spaces between the silver lines with a pen or pencil.Do half of the template.You can flip the template over to get a symmetrical piece.
Step 17: Attach the template to gray craft foam.
You can cut the negative spaces between the silver details with a craft blade.Use a pen to trace the template onto a sheet of gray craft foam.To trace the other side, flip the template over.
Step 18: Cut the craft foam and keep it aside.
You can cut the gray craft foam with a craft blade.Keep just the "silver" details, and discard the negative spaces.
Step 19: Use the gray foam as a guide to trace the mouthpiece onto cardboard.
Place the piece of foam you just cut onto the cardboard.Make a mark in the middle of the eye opening and then sketch the bottom of it.It is a good idea to use reference pieces of Kylo Ren's mask as a guide.Go ahead and finish your drawing, then set the gray piece aside.You can use another sheet of foam if you don't have anymore cardboard.There is an arch cut into the bottom of Kylo Ren's mouth.It's important to include this!
Step 20: Use a craft blade to cut out the mouth.
If you want a symmetrical mouth, cut out one side first.If you want to cut the other side, use the cut side as a template.
Step 21: Attach the segments onto the thin plastic.
A binder divider or a milk jug can be placed on a sheet of thin plastic.Put the cardboard aside.Take the segments from the reference pictures and put them on the top and side edges.There should be 4 narrow slit along the top edge.There are 4 squares on the left and right.
Step 22: Attach the plastic to the cardboard with glue.
Use a craft blade to cut the plastic.Attach it to the cardboard.The glue that works best here is an industrial strength glue.Hot glue will create too much bulk.
Step 23: The serving bowl is marked with a trace.
The serving bowl should be the same height as the cover.Set it aside and trace around it with a permanent marker.The outer cover for your mouthguard will eventually be made with this.Pick something with a rough texture.It is possible to use a sheet of thin plastic instead.If you are using thin plastic, it is a good idea to clean the surface.
Step 24: Referred photos can be used to refine the shape of the cover.
Inside the left and right side edges, trace about 1 inch.Don't leave the bottom curved edges the way they are, but trace over the entire bottom edge.A different colored marker is needed for this step.You will be able to distinguish which lines to cut later on.
Step 25: Referred photos can be used to draw the inner shapes.
If you look at the bottom of Kylo Ren's mouthguard, you'll see a couple of small circles.The right side edge has a rectangular shape halfway down.The notch on the bottom left has a fourth rectangle above it.There is a line between the fourth and bottom- left notch.
Step 26: Cut out the cover of the mouth.
Use a craft blade to cut out the cover.Cut along your inner refined lines, not the outer ones.A nail or a craft blade can be used to add some fight to the cover.If the bowl is too thick to be cut, use a Dremel.The cutting tool works like a screw driver, except that it cuts instead of drilling.
Step 27: It's a good idea to add some height to your cover.
There are 2 to 3 sheets of cardboard.Attach them together by cutting them out.You can glue squares of cardboard to the middle and sides of the cover.If you don't have cardboard, use craft foam.You might have to use 4 to 6 sheets.It's up to you how much height you add.Adding some depth to your mask is the goal.
Step 28: A painting station can be set up in aventilated area.
You can find a place without drafts or a well-ventilated room.Use a newspaper or plastic tablecloth to cover your work surface.
Step 29: Attach the craft foam with glue.
Craft foam is porous and absorbs paint.Before you paint it, you need to give it a smooth surface.Get some glue.Apply Mod Podge or white school glue to the foam pieces with a paintbrush.Add another coat after the glue is dry.Before moving on, let the glue dry completely.You might have to repeat the process a few times to get a smooth coating on your foam.
Step 30: Black spray paint can be used to paint the helmets.
Using a side-to-side motion, apply the spray paint from 8 to 10 inches (20 to 25 cm) away.Wait for the paint to dry and apply a second coat.Let the second coat dry.
Step 31: The craft foam pieces are gray.
You can do this with spray paint.It won't be shiny enough if you use acrylic craft paint.If needed, add a second coat.There is a curing time for enamel paint.It can take a few days, so check the label.
Step 32: The cover should be Glued to the base.
It is possible to use hot glue or industrial strength glue.It's important to glue down the sides and bottom.The nose bridge is alone on the top edge.You won't be able to add the silver piece if you glue that down.
Step 33: Behind the cover, put the silver piece.
Take the nose bridge out of the cover.Glue the silver piece down.Work your way outward from the innermost silver detail.You can either use hot glue or industrial strength glue.
Step 34: There are 2 connecting pieces between the helmet and the mouth.
There are pieces on each side of the mask that connect the neck guard to the mouth.Referred pictures can be used to sketch out the pieces on thin plastic, cardboard, or craft foam.Paint them black, then glue them to the inside of the neck guard.If you are using craft foam, make sure to coat it with a few layers of glue.These pieces are a few inches across.
Step 35: There is a black material behind the eyes.
If you want to cover the eye hole, you need to find sheer, black fabric and cut it into a large piece.Just behind the eye hole, glue the material to the inside of the helmet.Black plastic can be used for this.Make sure you can see it.