I only use the glue gun on the inside of the helmet. Now make the cheekbone sections by gluing the cheekbone template parts together and bending the cardboard and tacking it into place using a glue gun. Once the glue is dry cut out the cheekbone sections on the helmet inner surface. Next make the helmet outer surface- it is made the same way as the inner surface and is wrapped around and glued to the inner surface. Then I epoxy the joint at the back of the helmet. Getting the cardboard slightly damp (use a misting spray bottle) will make it easier to bend. This single piece is then wrapped around the helmet base form. This is done by cutting out the patterns on pages 1. The patterns on page 4 and 8 are glued together by cutting a slot in each piece on the center line and then fitting them together. The form is made from templates pages 4, 8, 1. This is used to help establish the basic helmet shape and is later removed from the helmet. The first step is to make the form for the helmet base. I then glued them to the cardboard with some rubber cement and then cut out all the pieces with an X- Acto knife. The best way to work with the templates is to cut them out and tape the separate sheets together. I was able to download some Fett helmet templates from the Dented Helmet forum. How to Make a Cardboard Costume Helmet: 7 Steps (with Pictures)For this example I'm going to construct a Boba Fett helmet from the infamous Star Wars character but these techniques can be used to make almost any helmet.
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