Space Balls put an amusing spin on the Star Wars universe. Instead of a supremely scary Sith villain, they had Dark Helmet. Instuactables user RoccoM made a replica of the costume. The most recognizable part of the Dark Helmet outfit is obviously the helmet. RoccoM made it from cardboard, which means it’s lightweight. A photo of the helmet is below. He says:

The helmet is way over sized so it had to be big yet wearable so I could turn my head. I created the round shape with flared bottom by cutting the pieces at a slight angle. The opening is created by laminating two pieces together at the flare so they would hold their shape. I used hot glue for everything. I reinforced the seams with a 1″ piece of cardboard glued to the inside.

Then he primed it and painted it black; he specifically used a satin Black Valspar primer and spray paint to cover the helmet and mask. He used a silver paint pen to add the accents.

Follow along with all the details at Instructables.