DIY Star Wars X-Wing Fighter Pilot Helmet Tutorial

DIY X-Wing Fighter Pilot Helmet Tutorial


Do your Kids love Star Wars? If so, this fantastic X-Wing Pilot Helmet makes for a really fun craft project that looks super impressive too. I've adapted this from some of the great tutorials found elsewhere on the web. This project uses half of a florist's hollow display ball, which can be purchased over at Amazon. Try it! May the force be with you!

What you will need

  • 1 x half hollow Styrofoam / polystyrene florist ball (8 inch for young kids / 10-12 inch for older children)
  • 2 x paper plates
  • 1 x sheet acetate (ideally yellow but clear is great too)
  • Thin white cardstock
  • Glue suitable for styrofoam / polystyrene (solid stick or cool glue gun)
  • Double sided tape
  • Paint or felt pens (yellow, red and black)


Buy Florist Hollow Foam Half Balls

FloraCraft Smooth Foam Hollow Half Ball, 8"
FloraCraft Smooth Foam Hollow Half Ball, 8"

You can't go wrong when purchasing a smooth foam Hollow half ball, the opportunities are endless with this foam product. With its' durable surface and high density you can easily paint, sand, glue and cut it with little effort. Great for school, home decor and crafting projects.

8 x 8 x 4 inches



Decorate both paper plates (inside). It's ok to be a little creative here but these will be your helmet's side panels. If your kids find the design too tricky to replicate, it's a good idea to get an artistic adult to mark out the black areas and let them handle the red and yellow parts!



  • Cut out the long strip that will make the 'Mohawk'. It will need to be about 2.5 inches wide and reach from the front edge of the helmet to the back edge.
  • Use a black fine pen to draw the stripes. The two outer yellow stripes should be slight thinner than the outer red stripes, and the central red stripe slighter wider again.
  • Paint the stripes



Add the red circular motifs to the helmet. Paint works best on styrofoam. This is perhaps the trickiest part of the project and it may require the steady hand of a grown-up to help trace the design out first.



  • Create the visor. This needs to come to the child's nose, so it's best to play around with templates made from newspaper till you're happy with a design. It should be about 3 to 4 inches deep (top to bottom).
  • Add double sided tape to outer front edges.
  • Attach to helmet using sticky tape on the outer top edges only.



Create the back panel from the white card. It will need to be roughly the same length as the plates. Stick this to back of the helmet. Styrofoam is not an easy surface to adhere to and you may need to use a cool glue gun. I found using a solid glue stick worked well and just kept applying pressure until it had taken. Add strips of double sided tape to the outer edge.



Pop the plates the 'wrong' way and stick to the double sided tape previously applied on the back panel and front visor. The red sections should face towards the front and align. It helps to add some glue to the top part of the plate and stick this to the helmet so it is secure and flush.



Attach the Mohawk strip to the helmet using double sided tape. It should overlap the visor. (Note this version contains the yellow striped front end, which is entirely optional and can be incorporated into the initial design or added as a separate panel of card, which is what I did.



Admire your handiwork and feel the force!


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