Make Your Own CLONE TROOPER Helmet Out Of EVA Foam | With Templates

[@3DPrintFarm]

This is most concise, easy way to construct an EVA Clone Trooper helmet of all time! Great job man!!!

[@TristanMaker]

Thank you! :)

[@jackychan92]

Please, please consider doing helmets from "The Bad Batch." I would happily buy templates to make Crosshair's Bad Batch and Imperial helmets.

[@SpriteLovuh]

That’d be awesome. Echo isn’t as cool as he used to be, but i’d love to have his new helmet

[@jasmineleilanikyle6064]

I very much appreciate you including these helpful videos for this! This has made building my son's Halloween costume SO much easier. That being said could you consider a few suggestions/requests I thought of while building this?: - Consider showing videos of you cutting out the pieces, that way we can follow along if we get confused or stuck. - More varied filming angles when you are attaching the pieces together so we can pause and zoom in if need be. (I can only speak for myself, but I'm very visual. So videos are the best which is why I went with your build, so maybe adding some other angles would be helpful. You have a very nice forearm, but it gets in the way sometimes and the viewer simply can't see what you are doing and exactly how you are placing the parts together). - Labeling each part (be it alphabetically or numerically) so that way it's easier to tell which piece we are working with and when as we follow along. (like with sewing patterns.). I often got very confused about which parts needed to go together even with the letters and mockup lines. But maybe if you could number or code each piece so you can say "Ok now put part A with part R" that would be very helpful. Thank you so much for these helpful videos! Hope you continue to do more!

[@TristanMaker]

I'm glad you like my templates! Thanks for the suggestions.

[@Guiltykilt]

Ok, now I'll save this video for my next comic con. The Ahsoka painting trooper (from clone Wars) is amazing and a great idea for cosplay

[@kadesoutherland3648]

Wow this looks AMAZING for a foam build. Didn't know you could make something this good until now

[@TristanMaker]

Thank you!

[@thecosplaynoobj3872]

I can’t wait for the new stormtrooper helmet build!! I did your first one. Not bad for my 3rd ever build but I think the next one using the new patterns to come are going to be awesome!!

[@TristanMaker]

Awesome! I'm excited to get that video out! :)

[@theplasticundergroundprops1035]

I love your foam builds, ill be picking up this template from your store for sure. Keep up the awesome work!

[@TristanMaker]

Thanks for the awesome comment! :)

[@ancientlordgaming8464]

Can you please please please do a comparison between yours and the hasbro phase 2 clone helmet I really need to decide which to get

[@KnutNukem]

Awesome weathering, thank you so much for sharing these amazing templates!

[@TristanMaker]

Thanks, no problem!

[@GMKGoji01]

…Wha…your EVA Foam helmet looks amazing!

[@TristanMaker]

Thanks!

[@collinmckeon107]

So solid. I remember when I made my first clone trooper helmet. I was like 15. A sanding bit would of make me helmet so much better. Hahah it was a rough one

[@martinroberts6608]

Great Video Tristan will defo make this can not wait to c u do the whole clone armour to go with this build.

[@TristanMaker]

Thanks! Yes I'm planning on making the armor :)

[@samsarmory521]

That is so cool

[@TristanMaker]

Thanks!

[@twitchstoleyourbagel]

Do you think I could have mesh in the black areas of the mouth piece for ventilation? I’m very claustrophobic and I would need some airflow

[@TristanMaker]

Yes! You can cut out the black areas once the helmet is built and glue in a mesh material. You might need to reinforce that area since foam isn't super strong. :)

[@heatherwood9570]

Dude that helmet is awesome! you should make the full armor for the phase two clone trooper.

[@TristanMaker]

Thanks! I'm slowly working on the armor right now! :)

[@SgtInvictus]

Hey so I’m using your armor and this helmet templates and I am making an arc trooper, how do I modify the fin to be the arc trooper fin?

[@TristanMaker]

For my armor I used the fin from my phase 1 clone helmet templates. Also the front under the grill is a bit different. The tip is pointy and the respirators are more round.

[@philjeske6886]

Are u planning on making the mandalorians rifle out of foam? Would really appreciate it if u could. Your templates for things are so easy to follow and i would so make it if u ever decide to do it.

[@TristanMaker]

Unfortunately I'm not planning on making one. But I'm currently working on more star wars things :) Kamui cosplay made an amazing replica of mando's rifle out of foam and she has a blueprint available.

[@marvelgeeks8585]

Thank you so much! This is an awesome tutorial, helped me a lot. Your template is really easy to understand too.

[@TristanMaker]

Awesome! Thanks for your support! :)

[@redheadhockey9071]

@@TristanMaker is it like the papers for it?

[@Tk-Toons]

I don't understand how to print off the templates in the right size for each piece of paper? can someone help me?

[@jakubskalski4172]

where i can find templates?

[@Duck3Dblender]

Hi, I'm a bit late to this, but what primer did you use before white spray paint, and is there a certain type of white spray paint to use (I cant seem to find the same one you are using in this video), Thanks!

[@Eismaus]

Hello. I'm not a native English speaker. I have trouble to correctly translate the inward and outward cut. Do you have a video, where you show the difference and how to cut it.

[@TristanMaker]

I don't really have a video, but if you message me on Etsy or Instagram I fan send you a picture of the types of cuts. Inward = tilt the blade towards the piece you are cutting out. Outward = tilt the blade away from the piece.

[@alicabelisova4893]

which shade of blue did you use? btw amazing video

[@TristanMaker]

Thanks! It was no specific color. I just mixed acrylic paints together to get it while looking at a picture of the helmet online.

[@FrozenFlameBrix]

I am trying to (long term) make a good amount of clone helmets, would you say that spending the money on 3 d printed helmets is more worth it than doing eva foam if you don't have much time on your hands? Which is the best option time wise, while still being not horribly expensive?

[@TristanMaker]

Buying a 3D printer and printing your own helmets is definitely better than buying 3D printed helmets long term. Making helmets out of EVA foam and finishing 3D prints takes about the same amount of time. The difference is that it might take more practice to get good with EVA foam than with just sanding and painting an already printed helmet. I find that building a helmet out of foam is more fun and less repetitive, but everyone has their opinions on this.

[@MyTube31581]

This is a great pattern. Always hard finding helemtes with such elaborate shape made out of foam. Mostly its 3d printed or donw with glassfiber. One question I have tough in regards to your foam: What is the density of the foam you use? Is it a high or low desity? I'm from Germany so I cant exactly use the shops you use so I'm asking :) Great work nontheless and wayyy underrated with just about 400 likes. Will subscribe and keep track of your great works :)

[@TristanMaker]

Thank you! I like using medium density foam for all my builds, but you could also use high density foam, it's just a bit harder to work with.

[@MyTube31581]

@@TristanMaker thank you very much! What are your next projects in planing? :)

[@TristanMaker]

For now I'm finishing the Boba Fett armor. After that, I might make his blaster and jetpack.

[@raymondhensley4677]

So I've been building the whole set of armor and I can't figure out how the back plate or the chest pieces go together

[@TristanMaker]

Watch the painting video for the clone armor. After painting it I show how each part goes together

[@andresr895]

Am I weird for not wanting to sand off/fill the seams because I Like that DIY look that seems give the whole project

[@AncientLordProductions]

no your not weird

[@lebaudy2970]

thanks you for you tuto and esty! do you think make Vador?

[@glyan1432]

What would you do to change the helmet for characters like CC Cody, Fox, or other commanders?

[@sofakingaamazing]

I’m very new to the world EVA foam. Would it be possible to sit while wearing full armor? If seams were to hold and not split, I’m thinking it’s a tough challenge for the foam to hold it’s shape. Your work is amazing btw!

[@TristanMaker]

Thanks! For my Mandalorian and Boba Fett armors, you can sit because there's no armor piece under the butt. Unfortunately the clone trooper armor has a big piece covering the butt so sitting is not an option without cracking the paint and foam.

[@sofakingaamazing]

@@TristanMaker Ah makes sense! Didn’t even take into consideration the paint cracking!

[@coltizar7]

Late to the game, but I've been struggling getting the 8mm pieces that look like bunny ears to stick together. They keep following apart, and I feel I have a good glue and heat gun

[@ravastarkskywalkermcqueen95]

Hey Tristan Maker Could you possibly make a video on how you create your foam templates off of a 3D printed piece? I’m actually fascinated about the different ways others create their patterns/templates, especially when they look absolutely screen-accurate. RAVA SSM95 out.

[@TristanMaker]

Thanks for the idea! This is definitely something I would like to make once I have the time.

[@austin-aka-8106]

I might be late to the party but how sturdy are the foam helmets and armor you make? I would hate to accidentally ruin one.

[@TristanMaker]

It mostly depends on how you paint them. Foam armors are flexible so they don't break easily. Most of the time the paint chips or gets scratched. I recommend doing research on sealing and painting methods to see what is the best option for you.

[@austin-aka-8106]

@@TristanMaker will do, one last question, not sure if anyone mentioned this but how much foam do you usually use for these?

[@TristanMaker]

It's hard to say, but for the main thickness which is 8mm, I use less than a 1x1 meter sheet.

[@austin-aka-8106]

@@TristanMaker alright, thanks for the answers!

[@jjbwood01]

Literally just brought your old plans abs my foam arrives tomorrow ahh dam it

[@slicknick7087]

What did u use for the visor? Can u share a link please

[@ofthecorn97]

This is so cool! You have excellent builds

[@TristanMaker]

Thank you! :)

[@LeftBehindBand2023]

How do I print the templates? I bought it but I don't know how to print them the right size

[@TristanMaker]

You can print the templates on any size paper and using any printer. Check out the sizing chart located in the pictures of the listing to find the scale that matches your size. Then, simply watch the printing tutorial video linked in the product description. All the information is there.

[@isaiahbair7690]

I wish I had a 3d printer, just think of all the possibilities for Star Wars cosplay

[@TristanMaker]

I have one but I still make my projects out of foam because I enjoy the process. But I guess making the templates from a 3D printed helmet is kinda cheating haha

[@kupambazua]

Hey so how big should I print out the template? Thanks for the video

[@NameHere2856]

He has instruction for that on the channel, it's also linked on his etsy.

[@PhotoWizard17]

Hi, thank you for the amazing tutorial! I was wondering what you used for the visor? I see you cut it out, but I don't understand what you used to fill in the space. Thank you 😊

[@TristanMaker]

I used a tinted welding shield. You can find them on Amazon. :)

[@PhotoWizard17]

@@TristanMaker So I'm trying to make the helmet and the foam is not sticking together. I'm using Lepage heavy duty contact cement and craft foam to make a trial version before I make a full helmet and it's not flexing at all and the glue won't stay, what am I doing wrong? Is there a difference between EVA foam and craft foam?

[@TristanMaker]

The biggest issue is the Lepage contact cement. I tried it and it just doesn't stick well at all. I recommend DAP Weldwood or Barge cement. And yes craft foam is EVA foam, but you really have to heatform it to make a helmet.

[@PhotoWizard17]

@@TristanMaker ok thank you, the biggest problem is I can't get those where I live, I'll have to order it online. Is it easier to do it with Eva foam? Should I just start over?

[@Sov_milk]

What 3d printer did u use?

[@TristanMaker]

I have a creality cr-10 v3. It's definitely not the best for the price now but I bought it a while back.

[@happygiraffe7893]

I bought the template awhile ago and am just now starting the build. The 8mm visor piece that has the 5 mm attached, am I supposed to cut that piece out seperate and trace on 5mm?

[@TristanMaker]

Yes exactly, you cut that part from the template, trace it on 5mm foam and glue it on the existing 8mm part

[@happygiraffe7893]

@Tristan Maker okay great thanks! I may have other questions as I go...first build!

[@lt.danhooper1635]

This might be a dumb question, but could I use 10mm foam in place of 8mm? I understand why you use several different thicknesses of foam for most of it, but where I live 10mm EVA floormats(which I already have some experience with) are nearly 1/3 of the price of 8mm cosplay foam.

[@TristanMaker]

You could totally use 10mm floor mat foam for this build, but it will be a bit more difficult to heat form and glue the parts. If you can get the thinner 6mm floor mat foam, that might be an even better option.

[@lt.danhooper1635]

@@TristanMaker Cool thanks for the help!

[@szp86]

5mm foam will work?

[@wesdraws]

So I want to make this helmet but when I measured my head circumference I found it’s 22 inches and a half so would I do the percent for 22 or 23 when I print it out

[@TristanMaker]

You can simply print the helmet at 100% scale. It will fit perfectly with some padding inside.

[@andycervantes1586]

Looks bad ass👍👍👍

[@TristanMaker]

Thank you!

[@militaryguy5360]

I can’t wait to start it will be my first build so I hope I make it right

[@TristanMaker]

Awesome! Have fun crafting!

[@carloko08]

incredible work, dude, congrats, a question, can i cover the helmet with glass fiber to make it strongest than just eva foam? is a similar process, right? the resines of glass fiber not "eat" the eva foam?

[@TristanMaker]

Thank you! I would not recommend covering the helmet with fiberglass or resin. One of the perks of eva foam is that it's flexible. To keep that flexibility, you can cover the foam with 5 coats of modpodge. It will make it stronger too.

[@carloko08]

@@TristanMaker wooo, great tips, dude, thank you again, i suscribe now 😃

[@Wetlooser]

Two questions 1.) is it really bendy/flexible 2.) can I use a hair dryer instead of a heat gun?

[@TristanMaker]

With all of the paint applied, the helmet is not very flexible, but won't crack if it gets dropped. Unfortunately a hair dryer doesn't get hot enough

[@hypecustomz4608]

after you add the filler primer, the footage that got corrupted, what grit of sand paper did you use ? great videos as always !

[@TristanMaker]

Thanks! I used 120 and 220 grit sandpaper.

[@hypecustomz4608]

@@TristanMaker thanks !

[@Michiii75]

Wich foam thicknesses are needed for this helmet?

[@TristanMaker]

All thicknesses required are specified in the product description on Etsy and on the templates directly.

[@Michiii75]

@@TristanMaker thanks i didn't know its in the descripton.

[@gamesandwich2]

I've just purchased the templates and printed them in 4 a4 size pages combined..... Is this the right measurement? Plz help

[@NameHere2856]

4? Definitely not, I think

[@maximekupke7311]

salut ! je suis entrain de me faire un casque de clone phase 2, tu as un lien d'achat pour la visière ? parce que je suis pas sûr de quoi prendre, en tout cas très bonne vidéo et très utile. Merci beaucoup !

[@tttxzzz]

So i’m planning on making the full armour set but how do i know what materials etc to pick up

[@l_204_l]

You'll want EVA foam recommend thicknesses 10mm, 6mm, 2mm, along with that a body suit usually you can find them at party stores

[@coryburbidge]

How do you determine how to resize the print to fit your person?

[@TristanMaker]

Refer to the sizing chart located in the pictures of the listing on Etsy.

[@ghivifahmi4252]

How do you fill the face slits?

[@Revan-og7jo]

How would you re-size the helmet to make it fit on a smaller head?

[@TristanMaker]

Watch the printing tutorial video linked in the product description on Etsy and check out the sizing chart in the pictures of the listing.

[@ottawashredder8472]

I would love to see a Biker Scout Trooper build!!

[@AncientLordProductions]

Hi i live in the USA and i was wondering if I could buy a premade one from you it does not have to be sanded or painted lets me know if you can please

[@TristanMaker]

Unfortunately I only sell the digital templates to help you make the projects yourself.

[@AncientLordProductions]

@@TristanMakerthats okay

[@Goose11632]

do you have the brand of the black, gray, and blue paint you used?

[@TristanMaker]

They are Liquitex basics acrylic paint, mixed with water

[@estarossa1847]

all the yellow grime def makes it look like it from a post order 66 clone rather than one during the clone wars

[@manuelcalle6506]

Do you think it could be made out of cardboard instead of Eva foam? Think you very much

[@alexanimation4520]

Do you think that I could make it with card bourd instead of Eva foam? I have made 2 helmets before.

[@TristanMaker]

Cardboard doesn't flex like EVA foam so some of the parts on the template won't work. If you are good at patterning you might be able to modify the template for those parts, but I can't guarantee the result.

[@alexanimation4520]

@@TristanMaker ok. Thank you.

[@alexanimation4520]

@@TristanMaker about how long did it take you on the building stage?

[@alanwhitaker3952]

awesome build....

[@TristanMaker]

Thanks!

[@ethanbrin1885]

Hey Tristan. I’m making this helmet, but when I try to attach the 5mm strip to the back it doesn’t reach all the way across. How do I fix this?

[@ideuu]

take a longer piece

[@theempress8886]

How do I print the template out so it’s scaled properly

[@TristanMaker]

Simply watch the printing tutorial video linked in the product description on Etsy.

[@AncientLordProductions]

My templates dont work some of the parts are too small or too big and dont fit did anyone else have this problem

[@TristanMaker]

Hi, I'm not sure how this can happen. You can write to me on Etsy with pictures of what is wrong and I'll help you the best I can.

[@AncientLordProductions]

@@TristanMaker thank you so much ill try to send pics its mostly the band in the indented part of the dome on the side and back thats too short or maybe the dome is too big idk also i tried to cut out the templates the best i can

[@AncientLordProductions]

@@TristanMakernever mind it works just a little right in the back area

[@szp86]

Hello 5mm foam will work?

[@bohnez0815]

Nice tut, and i like ur vids, but wich density do u use ? High or low density foam ?

[@TristanMaker]

I like to use medium density for helmets and high density foam for armors

[@gablava9099]

What’s every thickness of foam someone will need, I want to make this helmet but I don’t have any foam at the moment so I want to know what foam to get

[@TristanMaker]

All the thicknesses required are indicated in the product description on Etsy.

[@thatbird09]

The template is tiny. How much bigger do we need to scale the pattern ?

[@TristanMaker]

You need to print it in poster format for it to be full scale. Watch the printing tutorial video linked in the product description on Etsy, all the information is there.

[@hectormendoza2070]

Is there a specific way to print to scale or is it just ready to print the templates?

[@TristanMaker]

Watch my printing tutorial video linked in the product description on Etsy. All the information is there

[@nexusroyl8740]

you are my hero.

[@AK-uj7xr]

What would you say material costs could come out to?

[@JarJarThinks]

It’s probably around £20-£30 for the foam.

[@RXTransit]

Hi Tristan, quick question, What thicknesses of Foam is required for this build?

[@TristanMaker]

Mostly 8mm foam but other thicknesses for the details. If you get the templates, all the thicknesses are specified.

[@Xanlejo]

What material is this called in spanish?

[@rolandoquirino6270]

Luv ur videos...!!

[@TristanMaker]

Thank you! :)

[@charissediaz8472]

Can i use this templates with cardbosrd?

[@NameHere2856]

Cardboard isn't as flexible as the foam, but if you use several smaller and thicker pieces and then a sander, I'm sure it would be fine

[@imdaredevil84555]

can you make clone trooper weapons and light sabers maybe

[@Michiii75]

He made both already

[@Trudeauhitlist]

But where do we get the paper templates?

[@TristanMaker]

I only sell the digital PDF templates. They are available in my Etsy store

[@Trudeauhitlist]

@@TristanMaker thanks a bunch

[@David_R._8108]

Looks very good! Something looks a bit off though.

[@redheadhockey9071]

Is it ok to use super glue

[@TristanMaker]

You can use super glue on foam, but I only recommend it for small pieces that don't hold tension. Contact cement is a way better option for that

[@redheadhockey9071]

@@TristanMaker thanks

[@philjeske6886]

Will you make the Boba Fett helmet in the future?

[@TristanMaker]

Yes! I'm waiting for the trailers for the Book of Boba to come out. :)

[@team_xbox3.036]

PLEASE!! Can somebody explain me how to get the right head size??!?! I mean how the hell should i do it???

[@TristanMaker]

Hi, I have a printing tutorial video linked in the product description of the templates on Etsy that explains everything. You can measure the circumference of your head, check which scale it matches in the sizing chart (located in the pictures of the listing on Etsy) and follow the printing tutorial video.

[@JamesBricks06]

Where can you buy the foam

[@TristanMaker]

I'm from Canada so I get my foam from True North Cosplay. If you live in the United States, I recommend getting it from TNT Cosplay Supplies or Blick Art Materials.

[@JamesBricks06]

@@TristanMaker ok cool I live in the Uk and I found some on Amazon

[@kartoffeljames5644]

i ended up buying the template and i plan on making a clone trooper based off the attack on titan scouts

[@philjeske6886]

Could you pls make Kylo Rens Helmet. No one has a great video out there on how to make one

[@TristanMaker]

I'm not sure I'll have time to make it this year but I'll definitely add it to my list! :)

[@MainlineZoo6588]

wait is the entire template on one page???

[@TristanMaker]

Hi, the file is one page but by following the printing tutorial video linked in the product description, you can print it on multiple pages on any size paper and printer.

[@MainlineZoo6588]

@@TristanMaker Thank you :)

[@jonazizul7617]

you cool man

[@merrimanpatrick]

what MM was the foam?

[@TristanMaker]

Most of the helmet is 8mm

[@merrimanpatrick]

Thanks man! Bought the plans . Thanks for putting this together for everybody

[@TristanMaker]

No problem, have fun crafting! :)

[@spartstar45]

Can someone make a Clone tropper helmet and sell it or has to ask to Disney? I mean, I ask bcs maybe no... (Maybe)

[@TristanMaker]

Because my product is simply a digital pattern, I don't have to worry about copyright. It would not be legal to make helmets using my templates and sell them though since the design is of my own legal property. (And the copyright laws around selling star wars merch aren't very clear)

[@spartstar45]

@@TristanMaker so you as you, could sell it if you wanted? Bcs I hace to round the numbers and thought to make space some helmet and sell in the zone where I live, so technically if I make my own blueprint and stuff I could sell them? Srry If I am being so insistent...

[@TristanMaker]

If you make your own templates and sell helmets you made from them, you shouldn't have any issues. As long as you don't use the designs from other makers without permission there shouldn't be any issues. Selling starwars merch is not illegal and many do it, but some bigger shops that turn into brands would have to pay copyright to be able to sell starwars merch like helmets.

[@Onshapefornoobs]

where are the templates?

[@TristanMaker]

In my Etsy store, linked in the video description.

[@tateistg]

Can we please get templates?

[@TristanMaker]

They are on my Etsy store linked in the description.

[@josmarpinheiro2589]

republic commando foam,please

[@LaRamaRamirez]

can you make darth vader’s helmet out of eva foam pleaaaase

[@matthew-ph6xo]

how do i properly print out all the templates?

[@TristanMaker]

Simply watch the printing tutorial video linked in the product description on Etsy. :)

[@matthew-ph6xo]

@@TristanMaker thank you!