I've been trying to make a Darth Vader helmet and mask using cheap materials -- the mask shouldn't be a problem, because I can just cut, fold and paste black cardboard into the appropriate shape. The problem is the helmet. I tried making the helmet thus: I constructed a frame using strips of cardboard, then tried covering it with papier-mache. Unfortunately, the whole thing practically fell apart because the frame was too flimsy and sagged under the weight of the papier-mache. Did anyone hand-make their own Vader (or Boba/Jango Fett or storm/clone-trooper) mask? How did you do it?