Easy DIY Bo-Katan Helmet: Crafting from Cardboard

Welcome, fellow Star Wars enthusiasts, to this exciting DIY journey where we’ll guide you through creating your very own Bo-Katan helmet using just cardboard and a touch of creativity. So, without wasting any more time, let’s learn how to make Bo-Katan Helmet easily at home.

“A Mandalorian without a helmet is a disgrace to the armor.”

Bo-Katan Kryze

In the history of Star Wars, the helmet left a mark on Bo Katan’s evolution. Do you know her outfit has a meaning?

It is the most important part of the armor for her. You can find many helmets to buy online but making one on your own is just the satisfaction you see.

You might be thinking that it will be difficult and you will mess it up but you are wrong. After reading this blog post, you will figure out how to make Bo-Katan helmet at home easily.

So, let’s get started with this blog where I am going to take you through a very easy technique to make a bo katan helmet out of paper and cardboard.

The Complete Guide to Easy DIY Bo-Katan Helmet Making

In this tutorial, we are going to use paper and cardboard to make a DIY Bo-Katan Helmet. So, first of all, you are going to need some materials to begin your journey to making the helmet.

Materials Needed:

• Cardboard sheets (corrugated for sturdiness)
• Craft knife or scissors
• Pencil and ruler
• Hot glue gun and glue sticks
• Acrylic paint (silver, black, and blue)
• Paintbrushes
• Velcro strips or elastic for straps

Design Your Helmet

Begin by searching for reference images of Bo-Katan’s helmet online. I have shared these 3D model pictures of all sides of a classic helmet. Look and observe the helmet and make an image of this helmet in your mind. I have found this model on Facebook, you can visit the mentioned source for individual images.

Now, take a piece of paper and Sketch a simple design on it. Do not just sketch everything in one place. Break down into basic shapes like circles, rectangles, and triangles. Keep it straightforward to make the crafting process easier.

I suggest you take a bike helmet of your size. Then place the paper on the forehead area and mark the areas you need to cut. Here is a sample of how you should take the cutout for the forehead area according to your size.

Also, I am sharing another reference image of all the Bo Katan helmet templates that I have found on Facebook.

After looking at these shapes, you will have a pretty good idea of how to cut the templates to make the helmet-making process easier.

With a little study and figuring out the shape and sizes, you will be able to make this easy DIY Bo-katan helmet on your own, however, we have an easier way to do it below.

How to Make a Bo-Katan Helmet easily at home

Following the tips shared above, you can now proceed to the next steps. These steps are going to make your Bo Katan Helmet crafting easier.

Step 1: Cut Out Cardboard Pieces

Now that we have drawn the templates, rearrange the templates in a manner. First, make a group of templates which going to be used in the front part, etc.

You can follow the upper template design but you can also follow these cutouts to make the helmet. I am

After gluing all these 3 pieces together, you will get a shape like this shown below. After that, you can make the jaw part and lower head part and attach them too.

By looking at these two image diagrams, you should be able to understand the basic idea of making a Bo Katan helmet with cardboard.

A tip is you should be taking care of the sizes while cutting those pieces. No one can do it for the first time without doing it wrong. So, keep a lot of cardboard and be ready for taking next attempt to make it right.

Step 2: Assemble the Base

Start assembling the main structure of the helmet by gluing the matching cardboard pieces together. First start with the forehead area. Smothen the cardboard template and glue pieces together and make a stable round shape.

Ensure that the edges align properly, and use the ruler to maintain symmetry. Allow the glue to dry thoroughly and then cut the extra corners or non-align sides.

After gluing all the individual parts, you will get two sides of your helmet. You have to do the same process twice to get the same two sides like this.

Now that you have made all the big parts of the helmet, you can simply glue those parts together to make it a complete helmet.

Also, take two small cardboard pieces and attach them in the middle of the face area to make the helmet more steady and strong. I have taken these screenshots from a YouTube video here. You can watch the full guide of course.

Tip: Only assemble the parts to make the basic structure of the helmet. Do not glue the small detailing parts like the ear, antenna, and other small detailing.

Step 3: Add Details

Now that you have built the main structure of the helmet, proceed to add the details like the accessories attached to the helmet.

Add all the smaller cardboard pieces for intricate details. Bo-Katan’s helmet has distinct features, such as T-shaped visors and unique patterns, a round band in the back, etc. Be patient and take your time to get the details just right.

Step 4: Paint Your Masterpiece

Before starting painting, the most important part is to make your craft stronger. To do this, you need to get any white wood or paper glue like this one called Fevicol.

Mix the glue(60%)+water(40%). Take newspaper cut into small 2-inch square sizes and mix with the solution. Now spread the mix evenly on all sides of the helmet and let it dry.

Once the structure is complete, it’s time to bring your Bo-Katan helmet to life with paint. Start with a base coat of white then add silver and let it dry.

Add black and blue accents as per your design, ensuring a smooth and even finish.

Then mark your DIY Bo-Katan Helmet with the identical blue color.

After doing all that, get a market and draw the outlines on the helmet. Keep a good eye on the helmet while drawing the outlines, notice the shades, and also draw the forehead design of the helmet.

Tip: For a comfortable fit, attach Velcro strips or elastic bands inside the helmet. Measure the straps to fit your head snugly, and secure them using hot glue or adhesive.

Step 5: Final Touches

Examine your Bo-Katan helmet and make any necessary touch-ups. Add extra layers of paint for depth, and refine the details to match the character’s iconic look. Just like I mentioned before, add the shades, outlines, and tattoo designs.

At this point, you can also add your custom design to your Bo Katan Helmet. Also, explore our best picked Bo-Katan Costume Ideas here.

Congratulations, you’ve successfully crafted your very own Bo-Katan helmet from cardboard! Embrace your Mandalorian alter ego and showcase your DIY masterpiece with pride. May the crafting force be with you!

I hope you liked this DIY Bo-katan helmet-making tutorial. Share with your friends and visit Costume PlayHub for more Cosplay and Costume Ideas.