This year my five-year-old decided he wanted to be Chop-Chop (from Skylander Giants) for Halloween, all because of a Happy Meal toy he has. (Thanks, McDonald’s!) This meant I got to figure out how to make a cardboard costume helmet.
In case any of you are still working on Halloween costume pieces (no judging here, I just started his costume this week), I thought I’d share how I made it.
How to Make a Cardboard Helmet:
I actually used cereal boxes to make the majority of his helmet. To start with, you will need to cut a 2 inch thick strip of cardboard that fits around your child’s head. I used tape to piece two strips together to make it long enough to fit him, securing it in a circle with tape.
Then cut two more strips of cardboard, taping them inside the circle and crossing in the middle (as seen in the picture below). Be sure these two strips sit high enough for your child’s head to fit inside the helmet!
(Tip: A roll of paper towels is quite handy to hold your helmet while you work!)
You will notice one other addition in my picture, the start of Chop-Chop’s helmet decoration — a triangular nose guard.
At this point you can add in the start of a nose guard. You could also add in side pieces to the helmet, like ear guards. It all depends on how you want your finished product to look!
The next step is to fill in the top of the helmet.
I cut four triangular pieces to fill in the spaces left from the criss-crossing cardboard strips we have at the top.
To make them fit better I made a small cut upwards along the triangle’s bottom to allow me to overlap the bottom a bit, making the triangles rounder at the bottom. (To curve around with the shape of the helmet.)
Again, I used plenty of tape, cutting off any pieces of cardboard that kept sticking out, until I was happy with the result.
Our toy Chop-Chop has a blue helmet.
You could paint your helmet, but I chose to use some blue duct tape we had to help make our helmet a bit more durable and a little more water resistant. (Really hoping we don’t have rain!)
Once you have the basic part of the helmet completed, it’s time to get fancy!
Chop-Chop has a large crest on top of his helmet. I went with a slightly thicker cardboard for this, using two pieces hot-glued together to make it even thicker.
To get my little trick-or-treater in on the cardboard helmet making process, I asked him to color two large squares of cardboard the color he wanted the crest to be. (Paint would be great for this, but I like using what I have on hand when possible, so we went with a sparkly gold crayon.)
Then I tried to duplicate the shape of Chop-Chop’s crest. To fit it to your helmet, lay the helmet sideways on the cardboard crest you are creating and trace the top of the helmet. You may need to trim a bit more here and there, but it will be pretty close to fitting that curve.
I used lots, and lots of hot glue to secure our crest to the helmet’s top. (Tip: Do one layer of hot glue at a time, allowing each layer to dry before adding more glue. And remember, hot glue is HOT!)
Finally, I tried to duplicate the shape of Chop-Chop’s nose guard/decoration onto thicker cardboard as well. Then I hot glued it into place.
A homemade cardboard helmet to help transform any young boy (or girl) into character!
What costume pieces have you crafted from scratch? I’d love to hear about it!