Sometimes you just want the defend the universe from evil; when you’re feeling that way, the only thing to do is make a Voltron costume. Instructables user sixsixzero took about 150 hours over three weeks to assemble the giant mech and used materials such as cardboard, sheets of foam, Coroplast, and more. He gathered a ton of reference photos and built the costume piece by piece. Here’s how the head came together:
I started the head with a base part that I cut a hole in to fit my head. One you have that, you simply build up from there to get the look you want. I measured my motocross helmet for my basic measurements on how I wanted it to fit. I got this done fairly quickly, as I had already built the 4 other heads previously. I would recommend using a strap of some sort to hold it on….I didn’t do this and was straightening the head a lot. It fit nice and snug with the mask on, but couldve used that little xtra. I also added foam around the head hole for comfort and snug fit. The mask is just a plain white mask that I painted silver and blue.
Read about the process at the below link.