Okay, guys, so I’ve been wanting to make a Havoc Trooper helmet for a while now, and I finally got around to it. Let me tell you, it was quite the project!
Getting Started
First, I gathered all my materials. I decided to use EVA foam for the main structure because it’s lightweight and easy to work with. I also got some craft foam for the smaller details, some contact cement, a heat gun, a Dremel tool, and various paints.
Building the Base
I started by finding some templates online. Luckily there are a lot of resources for this kind of stuff. I printed them out, traced them onto the EVA foam, and cut out the pieces. This part took some time, but it was important to get it right. Then I used the heat gun to shape the foam, it curved the pieces to the right shape, and glued everything together with contact cement. It started to look like a helmet!

Adding the Details
Next up were the details. I used craft foam to create the smaller parts, like the ridges and the visor area. I also used the Dremel tool to carve out some of the finer details and to smooth out any rough edges. This was probably the most time-consuming part, but it really made a difference in the end.
Painting and Finishing Touches
Once all the pieces were assembled, it was time to paint. I started with a base coat of gray primer, then added the white and red details. I wanted to make it look battle-worn, so I used some weathering techniques, like dry brushing and adding some scratches and scuffs.
The Final Result
And finally, it was done! It took me a few weekends to finish, but I’m pretty happy with how it turned out. It’s not perfect, but it definitely looks like a Havoc Trooper helmet. I wore it around the house for a bit, and it felt pretty cool. My wife just rolled her eyes, but hey, she’s not a Star Wars fan. I even considered taking it to the next comic con, but I don’t know, it would be fun, maybe I will do that.
- Lessons Learned:
- Take your time with the details.
- A heat gun is your best friend when working with EVA foam.
- Don’t be afraid to experiment with weathering techniques.
So yeah, that’s my Havoc Trooper helmet project. It was a lot of work, but it was also a lot of fun. If you’re thinking about making one yourself, I say go for it! Just be prepared to put in some time and effort. But hey, it’s worth it in the end. Trust me.