Darth Revan Helmet — Free Star Wars Cosplay Pattern!

While Sci-Fi has never really been “my genre of choice,” there has always been a sprinkle of fantasy about the Star Wars franchise that has grabbed me. From the ultimate battle of light versus dark to the nuances of it’s sharp-tongued female warriors, Star Wars makes for a truly fantastic way to lose yourself in a great story. Not to mention a fantastic series to cosplay!

To celebrate Star Wars on this MAY THE FOURTH 2020, I’m releasing the pattern I created for Darth Revan’s Helmet. It’s my first ever Star Wars cosplay pattern, and it was one heck of a Kessel Run to bring it to you, but now it’s FREE to download as a printable PDF right here! If you would like to support my efforts to make this pattern, you can also make a donation in my shop! Thank you in advance for your support. 💜

All of us cosplayers know a pattern is not always as simple as just downloading, though. To help you put together this star wars cosplay pattern, I’ve added some basic instructions and construction photos below for your reference.

“Don’t everybody thank me at once.“

• 10mm EVA Foam Sheet
• 5mm (-OR- 6mm) EVA Foam Sheet
• 2mm EVA Foam
• Foam Clay
• Cutting Mat
• Tinted replacement visor — **Optional**
• Quick Cure Epoxy — ** Optional **

For this Star Wars cosplay pattern, you’ll need to start by printing my free Darth Revan pattern here. Following the printed key on Page 1, cut out each piece along the solid black lines. Some pieces will appear on multiple pages, and need to be overlapped and taped together to create your final pattern piece. Here’s how my original patterns looked when cut out.

Carefully lay your cut patterns on to the appropriate foam thicknesses (10mm, 5mm, or 2mm). I find it helps to lay all patterns for the same thickness out at once—sort of like fitting a puzzle together! This way you can make the most out of your foam. Once they are fitted together, I like to use a few straight pins to secure my pattern while I trace.

Using a sharpie or similar soft felt marker, trace the outlines of your patterns, and mark the registration keys. I leave a tick mark along the outside, then mark the same line on the inside of the pattern once I remove the paper. One at a time after removing, be sure to also mark each sides’ letter, and dotted registration lines too. This makes it super easy to glue all your pieces on together later.

Each pattern piece is labeled with the foam thickness you’ll need, as well as how many of each piece you need. Be sure you remember to flip your pattern over for all pieces that say “Cut 1 Reversed,” and be sure to label which is “Right” and “Left.”

Once all your pieces are cut, give them a quick once over with your heat gun to seal the foam.

Once all your pieces are cut and heat sealed, get to gluing! Be sure to use barge cement in a well ventilated area, according to package safety instructions. Apply a thin, but fully covered coat of barge cement to both sides you are gluing. Allow each side to dry, and carefully connect, starting with one edge and finding your matching registration marks.

For gluing this specific Star Wars cosplay pattern, you’ll begin with each of of the 10mm pattern pieces. Once all your 10mm pieces are glued, you can heat form in small sections to smooth out your curves. You can also use a Dremel to sand edges smooth if necessary at this time.

FYI: Barge cement can sit for a LONG time and still be fine for gluing. Don’t rush, and let it get nice and dry before attaching pieces for the strongest hold.

Your base is assembled… but if you thought you were all done with that stinky barge cement, THINK AGAIN! Now it’s time to affix your 5mm (or 6mm) and 2mm detail pieces. Each pattern piece is labeled with the appropriate foam thickness.

Start with the 5mm pieces, as they go below your 2mm detail layers.

Once you’ve added the 2mm details on the front face of the helmet, grab your foam clay and use a small bit to smooth out the front most 2mm detail layer (labeled with a “W” and “Z” side on the pattern). Our version of Darth Revan’s helmet has a subtle curvature on the front silver panel we are mimicking with this top layer and foam clay.

Once all your pieces are assembled, it’s time to seal the cracks with some Qwik Seal. I recommend having a small cup of water and some paper towels handy for this step. Apply a small amount of Qwik Seal directly on to all the cracks left between EVA foam pieces. Smooth with a wet finger, and clean up any excess with a wet paper towel. Allow to dry overnight.

Once your Qwik Seal is dry, seal all your foam with Plastidip, Flexbond, or your preferred EVA primer of choice. Be sure to follow instructions on the product you choose!

When making Darth Revan’s helmet, I followed Punished Prop’s creature cast rubber tutorial on YouTube. I found it was nice to be able to build up a thick coating of sandable rubber — However the results are just as nice with Plastidip, so I don’t recommend going out of the way to try Creature Cast if you don’t already have all the tools needed to do so.

I finished Darth Revan’s helmet with hand painted acrylics and lots of “distressed” details. If you are looking for a smoother, shiny finish, I recommend acrylic airbrushing your paint. Just be sure to let your primer dry completely, then section off color blocks with some “delicate surface” painter’s tape. You can then finish it off with a high gloss acrylic coat.

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Congratulations! The force was with you, and you have succeeded at making Darth Revan’s helmet with my star wars cosplay pattern! Will you use your newfound power for good? Or will it turn you to the dark side? * Palpatine laughter ensues *

For more photos of my completed Darth Revan helmet, check out my Portfolio!

**Full Disclosure: I get credit when you purchase items via my Amazon links in this blog post! Any profits I receive from Amazon will go directly back into more blog posts and tutorials. Thanks in advance for considering a purchase 🐲