Making a Dark Helmet costumes from Spaceballs might not be quite as much work as building a Darth Vader one, but it’s still not simple. Tony made his after wearing other Spaceballs costumes with friends at conventions and to construct Dark Helmet’s giant helmet, he used a laundry tub, party tray, and putty. I appreciate the resourcefulness!
He got a face shield from the hardware store and installed it to make the helmet wearable; he attached it to the back of the helmet with styrene and bolts. His friend Jack Doud of Bloody Plastic jumped in at this point and started work on the faceplate. He also got creative with supplies:
With the dome positioned I could take some measurements and begin making the faceplate. We round a drain part at the hardware store that would work for the mouth. The lid off a putty tub became the ring around the mouth and the rest of the faceplate was pieced together out of styrene.
Doud built it from there and performed a lot test fittings to make sure the faceplate fit, was positioned correctly, and could flip up. Tony eventually added a small magnet to keep the face shield up.
Read more about the build at Bloody Plastic.