We went to the Halloween store and found an Army guy helmet that was the right shape (for the top of the head). I altered it by adding poster board (the thickest I could find) extensions with the glue gun. I had to cut out and bend the cardboard into the right shape for the cheek area.
I did a layer of paper mache for more stability (I used modge podge glue)
Next, I coated everything with spackle (the kind you would patch a hole on the wall). The kind I bought goes on pink and turns white when it's dry.
Sanded and painted and dabbed on silver paint here and there for the scuffed/battled look. And lastly, I sprayed the inside and outside with a matte clear coat.
And... Waa Laa! Boba Fett!
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