How to Make a Trojan Helmet Out of Foil

By Molly Thompson
The fierce Trojan warrior has become a mascot for school sports teams.

Making costumes for Halloween, school plays or role-playing games can save money over buying ready-made costume items. This is especially true of helmets, which can often cost more than the rest of the costume combined if purchased commercially. Fortunately, you can make homemade helmets from readily available household materials. An empty gallon milk jug can be transformed into a variety of helmet styles, including a Trojan warrior helmet.

Wash and dry the empty milk jug. Cut off the entire handle section, leaving the top and flat sides intact.

Measure the bottom edge around the cut milk jug -- the bottom of the helmet. Draw a half-circle on the cardboard using the measurement as the diameter. Cut out the half-circle. Use duct tape to attach the straight edge of the half-circle. This flap hangs down from the back of the helmet to protect the neck and upper back.

Cover the surface of the cut milk jug with aluminum foil. Glue the foil to the milk jug or secure it by folding the edges under and taping them. Cover the attached cardboard half-circle with foil as well.

Cut a 10-inch by 4-inch piece of red construction paper. Fold it in half lengthwise. Glue the pipe cleaner into the fold with 1 inch protruding at each end. Glue the folded paper together. Allow the glue to dry completely for 30 to 60 minutes. Cut into the construction paper on the non-folded side; cuts should be 1 1/2 inches deep and 1/8 inch apart.

Poke a small hole in the center top of the helmet. Measure 10 inches from this hole down the center back of the helmet and poke another hole. Insert one of the pipe cleaner ends into the hole on the top of the helmet. Fasten it inside with duct tape. Pull the red fringed piece down the back of the helmet and insert the other pipe cleaner end into the hole. Use duct tape to fasten it inside the helmet.

About the Author

As a national security analyst for the U.S. government, Molly Thompson wrote extensively for classified USG publications. Thompson established and runs a strategic analysis company, is a professional genealogist and participates in numerous community organizations.Thompson holds degrees from Wellesley and Georgetown in psychology, political science and international relations.