How to Make a Children's Space Helmet

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Aliens come in all shapes and sizes in science fiction, and often these creatures in classic films are depicted wearing helmets. To create an alien costume for a small human actor, rather than resorting to expensive masks or makeup, make a space helmet out of paper-mache. Then, embellish the helmet with decorations to make it look more unique and convincing enough for the likes of NASA. This is a fun space suit accessory for a Halloween costume or space adventure cosplay. Simply follow the crafty step-by-step instructions in our tutorial and prepare for blast-off!


Things You'll Need

  • Balloon

  • Newspaper

  • Flour

  • Water

  • Salt

  • Mixing bowl

  • Marker

  • Scissors or craft knife

  • Plastic cups

  • Duct tape or masking tape

  • Spray primer

  • Silver spray paint

  • Black drinking straws

  • Hot glue gun

  • Plastic transparency sheet

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Blow Up a Balloon

Blow up a balloon that is slightly larger than your child's head.

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Tear the Newspaper Into Strips

Tear six sheets of newspaper into 5-inch strips.

Mix the Paper-Mache Paste

Mix equal parts of flour and water in a bowl to form the paper-mache paste. Add 2 tablespoons of salt to prevent mold growth. The exact amount required depends on the size of the balloon: Begin with 2 cups of paste and make more if needed.


Dip and Apply the Strips

Dip the strips one by one in the paste; then smooth them onto the balloon. Cover the entire balloon with overlapping pieces. Allow the material to dry completely before adding more layers.


Add More Paper-Mache Layers

Apply three more full layers of paper-mache strips.

Allow the Material to Dry

Allow the paper-mache to dry thoroughly between each layer.


Pop the Balloon

Pop the balloon by sticking a needle through it.

Create the Head Hole

Then draw a hole in the paper-mache balloon cover with a marker large enough for your child to fit his head through. Cut the hole out with scissors or a craft knife, making sure to trim away any excess, so the edges are neat and clean. The helmet will rest on your child's head, ending just below the chin.


Make the Face Hole

Draw a rectangular hole with your marker in the front of the helmet for your child to see through. The hole should measure 4 inches by 6 inches with rounded corners. Then cut out the hole with scissors or a craft knife, again trimming away the excess to create neat, clean edges.



Cut and Glue the Antennas

Cut the bottom inch off two disposable plastic cups. Hot-glue a black drinking straw to the center of each cup end to simulate a radio antenna.

Tape the Antennas to the Helmet

Duct tape or masking tape these cup bottoms to the sides of the helmet over the ears, with the open sides pressed against the helmet.


Secure the Antennas

Cover the cup ends in two layers of paper-mache to secure them in place. Let the paper-mache dry.

Paint the DIY Astronaut Helmet

Spray the helmet with two thin coats of primer, followed by two thin coats of silver spray paint. Let each coat dry thoroughly before applying the next coat.

Finish Your DIY Space Helmet Project

Hot-glue a dark piece of plastic transparency to the inside of the helmet to form a visor. Your child will be able to see out, but others will not be able to see in.


Plastic transparency sheets are available in teacher supply stores. They can also sometimes be found in office supply stores.

Glue an American flag to the front or side of the helmet along with the name of a space mission. You can find or create these online and print them from your computer.

Cut a piece of vacuum hose; then glue one end to the back of the helmet and the other to the body suit or backpack to simulate a breathing apparatus.



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