Bo Katan Helmet (Rebels) DIY (free patterns) @ZolusProps
Bo Katan Helmet (Rebels) DIY (free patterns)  @ZolusProps
Uploaded November 2020 | Updated September 2026, 1 week ago
In this video I make a Bo Katan cosplay helmet from EVA foam inspired by the Star Wars show Rebels. Hopefully this how to video helped you with your diy project or inspired you to start one.

patterns: facebook.com/permalink.php?story_fbid=1031522360592848&id=291491094595982

Materials Used: 5 mm EVA foam, 2 mm EVA foam, replacement grinding visor
Adhesives Used: contact cement, superglue, 2 part epoxy
Sealers: Mod Podge, DAP Alex plus
Paints: black spray paint, blue airbrush paint, pewter rub and buff, white airbrush paint, black testors model paint, gray testors model paint, charcoal gray spray paint
Tools Used: airbrush/compressor, scissors/xacto knife, heat gun, paint brushes, hot glue gun, cutting mat, Dremel 4000 Rotary tool

Mando cosplay playlist: youtube.com/playlist?list=PLW5gednRjnqWR_2Ms5uHqyrFNKn7_bWUc

Like to try tubebuddy? link: Tubebuddy.com/Zoluspropsandcosplay

superglue: amazon.com/gp/product/B01NCP64T0/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B01NCP64T0&linkId=46ec2c8eba6309487c712d67265e7d50

Mod Podge: amazon.com/gp/product/B003W0XR8M/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B003W0XR8M&linkId=52dfa67f7aedab255a6e6405d5042687

Dremel 4000 rotary tool: amazon.com/gp/product/B00LUU2XFO/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B00LUU2XFO&linkId=3d29d3bc00ec657025c81f1c9c15740f

contact cement (pint)- amazon.com/gp/product/B0006MXRY8/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B0006MXRY8&linkId=41740abe560483c9094e47589e967a6f

5 mm EVA foam roll: amazon.com/gp/product/B084NXH8WD/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B084NXH8WD&linkId=bb6e5b25ccdc151941ab3f1b70b47731

heat gun: amazon.com/gp/product/B004NDX7O6/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B004NDX7O6&linkId=cee8c8c6088906c8feae340821607f6c

cutting mat: amazon.com/gp/product/B00L5I8RKQ/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B00L5I8RKQ&linkId=9ddfd405352c11ac46391ef89ec6c8c2

2 mm EVA foam sheet: amazon.com/gp/product/B0018N26IW/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B0018N26IW&linkId=8f6c3e8dd7549123096b832c94cfdf12

black spray paint: amazon.com/gp/product/B0010P63NC/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B0010P63NC&linkId=7ef62daeb05c9d4601e34e64e624dd01

pewter rub and buff: amazon.com/gp/product/B00A2CGWQW/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B00A2CGWQW&linkId=92a9211d4aed7a723d490d3c1a299c85

airbrush kit: amazon.com/gp/product/B006HJCP8S/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B006HJCP8S&linkId=266de5a4c3ae634791ebd7ff3fddce15

hot glue gun: amazon.com/gp/product/B01178RVI2/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B01178RVI2&linkId=4fd72918d5e81fae8fc553354a53bbac

replacement grinding visor: store.cyberweld.com/hobart-face-shield-replacement-lens-770580.html?utm_medium=shoppingengine&utm_source=googlebase&gclid=Cj0KCQiA48j9BRC-ARIsAMQu3WRjVvmNr7-aMLj4QU0pod_PtKCMN4qU8r5YFr4SkWyYOF-lQ9b6HNoaAluiEALw_wcB

white airbrush paint: amazon.com/gp/product/B001DO384W/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B001DO384W&linkId=21199a7e85dc176b4f2360958b689383

blue airbrush paint: amazon.com/gp/product/B001DO1LDC/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B001DO1LDC&linkId=0b69b6b12625297e3c4268ca73c54685

testors black enamel: amazon.com/gp/product/B004O7GGYO/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B004O7GGYO&linkId=97446812d4f996350a23ddbf4ff20955

testors gray enamel: amazon.com/gp/product/B0069FYOAW/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B0069FYOAW&linkId=f4dc9be92ccfb7c6e3147c75a85bbcd7

DAP Alex plus: amazon.com/gp/product/B000H5VWXM/ref=as_li_qf_asin_il_tl?ie=UTF8&tag=zolus777-20&creative=9325&linkCode=as2&creativeASIN=B000H5VWXM&linkId=da85ecdcbd0654ee39df4bd084749a58

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Bo Katan Helmet (Rebels) DIY (free patterns)

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