Clone Trooper Phase II Helmet

Phase II Clone Trooper helmet made for cosplay and display.
The model is sized for generic head shapes and split into parts to make printing and assembly easier, while keeping accurate proportions.

This helmet works well for first-time armor builders but is detailed enough for more experienced cosplayers.

Fit & Scaling

• Designed to fit most adult heads
• No scaling needed for most users
• A test ring is included and strongly recommended before printing the full helmet

Test Ring (Print This First)

Before printing the helmet:

1. Print the test ring at 100% scale
2. Try it on
3. It should fit comfortably over your head without squeezing
4. If needed, scale the model evenly (for example 102–105%)
5. Print the helmet parts at the same scale once the fit is correct

Skipping the test ring can result in a helmet that doesn’t fit.

Assembly

Gluing

• Test-fit all parts first
• Use super glue or 2-part epoxy
• Hold or clamp until fully cured
• Reinforcing seams from the inside is recommended

Plastic Welding

• Use a soldering iron or plastic welder
• Weld seams from the inside
• Add spare filament for strength
• Sand seams on the outside after

For best results, many builders combine welding and glue.

Finishing

• Fill seams with filler or body putty
• Sand gradually
• Prime before painting
• Paint and weather as desired

Background

The Phase II helmet was introduced late in the Clone Wars as an upgrade over Phase I armor.
It offered better protection, improved visibility, and more advanced communication systems.
The design later influenced early Imperial stormtrooper helmets.

Notes

Any Questions, message me

For personal use, cosplay, or display only.
Not affiliated with Lucasfilm or Disney.