Storm Trooper Head Cover

Being a true Canadian I couldn't let Red Green down and not enter the Duct Tape Contest.

I was trying to come up with something unique to make with duct tape, then it came to me while my wife and I were eating dinner at one of our local golf courses! I saw someone's golf bag that had the gopher from Caddie Shack as a club head cover. Since there was no way I could make a gopher ( I couldn't find furry brown duct tape anywhere ) But they had black and white. What is black and white...? The dark side and the good side of the force!! Star Wars... my kids loved Star Wars! Wait a minute... storm troopers are black and white! Wow, sometimes I scare myself with how my thought process works.

I recently saw on Instructables a fellow who made a replica divers helmet entirely out of a 1/4 '' thick black foam floor mat ( neat idea ) so I decided to use it as a base for the storm trooper helmet. The rest is duct tape, masking tape, crazy glue, hot glue, a used head cover from a thrift store and a small piece of 5'' pvc pipe to act as a mold.

I calculated that I would need around five inches in diameter for my driver to fit, so I found a piece of 5'' PVC pipe to use as a mold, with an old plastic bowl taped to the top.

Starting with a piece of foam 16'' long ( circumference of the outside of a 5'' piece of pvc pipe ) X 11'' high I put painters tape on to what would be the outside and drew a line 3 3/4'' down ( one quarter of the circumference ) and divided it into 1'' increments.

I made up a plastic template to use as a guide to cut the foam. After cutting out the foam with an Olfa knife I wrapped it around the pvc pipe and taped it together so I could glue the pieces together to form the dome. I used crazy glue, but hot glue would have worked just as well, and it probably would have saved me from gluing my finger tips to the foam!

Once the dome was complete I glued a triangular piece of foam 3'' x 1 1/2'' between the joint directly below the dome, then by using some fairly course sand paper ( 80 grit ) I smoothed out the dome.

I measured up 3'' on the back side and folded the foam back on itself and held it with a few clothes pins so I could glue the two circular light vents . I used a piece of 3/4 '' plastic pipe to get them even.

Once those were glued in place I removed the clothes pins and glued the back permanently to the inside. I had to add a couple of relief cuts to get it to go tight inside at the back.

Next I made a paper template and traced it onto a piece of foam and cut it out for the face shield and did a test fit by temporarily holding it in place with masking tape.

I cut a 7/8'' strip of foam for the head band and added the two pieces above the ears.

Once I was happy with the positioning of every thing I out lined the pieces with a marker. I made sure not to have any tape under the face piece or the head band so I could glue foam to foam

I then proceeded to cover the exposed area with white or black tape ( triangles for the dome ) , including the head band and face piece, leaving any areas that required gluing free of tape.

Using hot glue I fastened the face shield and head band in place and added a few pieces of black tape across the bridge of the nose and below the eyes to finish it off.

I purchased an old Callaway head cover from a thrift store, which I then hot glued inside the storm trooper helmet, turning it into one galactic head cover.

I haven't had a chance to take this out on the course yet, but since it's duct tape and foam it should hold up well against the weather and I look forward to the amusement it will provide my golf buddies. I think Red Green and the members of the Possum Lodge would be proud :-)

You know how I have to end this.

Thanks for checking this out and

May The Instructables Force Be With You !!!

Cheers