I got my hands on a Rubies Darth Vader costume almost two years ago from a good friend. I just upgraded the helmet the way I want. After looking up all kind of pics online. I finally finished it a month ago. I got some pics below of what I did to share.
Here’s a pic of the helmet before any work.

Another view.

This is not the first up grade.I had a lot of mistakes to fix. At one time I painted the whole thing black and had big flat lenses.


I had to sand down this Hulk brow I made before, and work on the nose bridge.

After seeing that just a cover up won’t work. I decide to just cut the bridge out.


I use a paper like clay that dries great and easy quick sanding. After a good paint, it’s like plaster. Like.

Get those eyes smaller.

Sand and primed and ready for a QC check.

All done sanding and my cuts made on the bridge.

Got some dollar tree sunglasses and these are going in my Vader. I spent over 30 bucks with shipping for the flat set I had before. Boy..

Got the gunmetal paint dry and read. Time for the black paint now.


I use a car filler prime and a car paint for the mask and dome.

I like it. Now I love a lil bit of nicks and cts on my sith. No super new Vader in my watch!

All DONE!!! The fan inside works and now all I need is a good mic for my amp.


Me as Vader in the Vader Strikes YouTube fan films by Golden gate Knights and the Stunt People.