Boba Fett Helmet - Ventilation

If you're planning on wearing your helmet for any amount of time, heat and ventilation will be a problem. There is no place for the warm air to vent out, much less cool air to circulate through.

These cuts will also improve your hearing while you're wearing the helmet.

Begin with the left ear. Cut this part of the plastic with a hobby knife, taking care not to widen this section too much. A rotary tool works well here but the blade heats up the vinyl and produces a foul smell.

Next, we'll work with the right ear. You'll need to remove the cap that holds the rangefinder in place. Do this with a combination of prying it off with a screwdriver and cutting the seam with a rotary tool.

After you've removed the cap, take a hobby knife and cut out the rectangular piece show here.

With a regular drill, drill out the three holes below your new cut as well.

The last place we'll cut is in the back of the helmet. With a hobby knife, cut out all of the six oddly shaped designs show here.

Now that all the ventilation holes have been cut, you can begin to line the inside of the helmet with screen door material, found at your local hardware store. The screen is available in either black or silver and costs about $5 per roll. You may even be able to get scraps of the material for free if you ask.

Using a hot melt caulk gun, secure the screen on the inside of the helmet. Make sure you completely cover all the edges, so you won't hurt yourself on a jagged edge.

Repeat the process for all of the holes.