@addenkad - polystyrene (a.k.a. Sintra) is a semi-flexible lightweight plastic which can be formed into various shapes when (gently) heated. Last time I read, the recommended method was either a heat gun ($25-50 for a basic one at a hardware store) or dipping it in boiling water to soften it before forming (but don't let it come in contact with the pot itself, or it may adhere).
Some relevant links (related online communities which specialize more heavily in costuming):http://www.bobafettfanclub.com/manual/costume/http://www.thedentedhelmet.com/wiki/Templateshttp://mercs.firespray.net/forum/index. ... tion=forum
There's a treasure trove of information on any of those sites -- far too much to list individually here.
If you're so inclined, it is definitely possible to make armour from cardboard and related paper products; I made a Boba Fett costume in 7th grade for Hallowe'en entirely out of cardboard (ignoring the obligatory jumpsuit and vest). Cardboard is lightweight, and while not traditionally durable, it can be convinced to stand up to some beating with the proper tools and patience.http://www.instructables.com/id/How-to- ... /?ALLSTEPS
<-- Cardboard costume. Pretty good.
You could also make it out of metal, but...yeah. Good luck (it's tough). I have seen online accounts of a few skilled welders and metalworkers pulling off entirely metal sets of armour (there was one impressive metal helmet I remember as well -- I'm sorry I didn't keep the link to share, because it was beautiful).
Here's one: http://www.thedentedhelmet.com/f23/full ... met-32513/
And there's a build log covering start-to-finish on a welded steel (or maybe it was aluminum) helmet, but I can't find it anywhere (hint: if you do stumble across it, please post it here, because I want to put it in my "fanboi" link folder
There's also fiberglass, of course, but...I don't even.
If you want to do a Jango-style shiny metal effect, there is a method involving plastic and something called "Rub-n-Buff," which is a wax-based polish used to keep antiques looking acceptable. You just rub it on and polish very vigorously for a few minutes, making sure the wax gets hot enough to melt evenly across the surface as you go, and the end result is almost indistinguishable from metal to anything but the closest inspection.
Rub-n-Buff: http://www.amazon.com/Rub-N-Buff-Finish ... 607&sr=1-1http://www.youtube.com/watch?v=rItYKAEbt90
<-- seriously impressive result using Rub-n-Buff. Just watch the amazing transformation
I could go on about this for hours. I have read probably hundreds of tutorials and build logs over the last ten to fifteen years, but I have never been able to justify the time or expense to build a new set of armour (even though all told, I could do it for between $200 and $500 for a basic, sturdy, good-looking custom-build -- I just really want to scratchbuild, which means weeks and months of time and effort and possible several iterations as I make mistakes and learn from them).
If I ever find my big link list of armour-building tutorials and stuff, I will definitely post it on the forums here. I may never find it, though, as my hard drive has undergone several truly massive reorganizations in the last year or two.
If you want a premade helmet kit to start from, Asok's kit is very popular: http://mercs.firespray.net/forum/index. ... ic=41803.0
($175 shipped anywhere in USA).
Mandoa.Org - Bringing together the Mando'a Community.