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eva-guy01's avatar

Zaku Mecha Helmet Tutorial

Step by step tutorial on how to make your own Zaku mecha helmet out of craft foam (or rubber sheet in some regions). Be sure you follow it based on the size of the head you plan to have it worn on. This is very basic so feel free to improve on it in terms of designs, gimiks and colors.

Drawn in vector via CorelDraw.

What is a Zaku? [link]

What is Craft Foam? [link]
(usually used for Flip-flops)

Where can I buy them?
If you are from Metro Manila, Philippines, information on sources can be found at FilCosplay Forum's Cosplay SOS Directory: [link] You would need to be a member to view it, membership is free.

If you are from other countries, try to find your nearest supplier online.

Will you be making the whole Zaku body?
Soon. If im successful, will post a tutorial if i can.
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UnicornTheGundam's avatar

Sieg Zeon

Sieg Zeon

Tacotitan's avatar
This will be most useful.  Thanks!
luckydragonbb's avatar
this will help me so much. Thank you.

Seig Zeon you Feddie!

WarEaglet's avatar
Hi, eva-guy01.  The link on where to buy craft foam appears to be broken.  Looking to make my first foam costume.  Help please as to where I can buy craft foam!!! :) Thank you thank you!!!

eva-guy01's avatar
Estanislao Merchandise
Tel#: 645-3017

Photo of store:…

How to get there:

Jeep: From Aurora Blvd take any jeep that has the sign "Marikina Bayan" and it will take you all the way to Estanislao Merchandise. To get back, go to the corner of JP Rizal & E.Dela Paz and take any jeep that says "Cubao Farmers".
WarEaglet's avatar
Thanks a lot, eva-guy01! Found it! :)

ltgsniper122's avatar
I hope u will have to Tutorial up soon on how to make the Zaku's body, also I love your instructions, much better to understand than others I've looked at.
TimLecman's avatar
This a great help eva-guy thanks. I'm trying to build a Gouf costume, can you give me some pointers on what to use for the body and how to put it on? Thanks.
eva-guy01's avatar
It may take a while to illustrate you some tips, but if you have facebook, you could view this free tutorial from Clive Lee, the "Gundam Guy" cosplayer of Singapore. You can check his deviantart: [link]

Its pretty complete costume guide in building a Gundam costume, it could help you build your Gouf since its pretty squarish. Good luck!
TimLecman's avatar
thanks and sorry for the late reply, I couldn't log into this no matter what.
I've contacted him and got some tips thank you very much.
gammanet's avatar
this is great, one question, if I dome the peice over the top wont the mid edges kinda bubble?
eva-guy01's avatar
It would if the lower piece is significantly smaller. And if it cant be helped and large gaps appear, you can cover it using melted glue stick and a glue gun before painting a primer latex paint.
Masetsuke's avatar
a question.. can you help me with something?

the something.... how do i draw the eye shapes? symmetrically.? because i've been wanting to make those shapes of my OC armors.. ^___^. please and thank you~
eva-guy01's avatar
You can do a "cheat". Attach the rectangle (the top curve of your crown) and the longer rectangle circling your face. Then trace the empty space where the eye-shapes are supposed to be with a pencil on a flat sheet and simply polish the trace into a good eye-shape. Then make two of them.
Masetsuke's avatar
\^___^ that is awesome! thanks a lot!

common sense kinda kills me everyday~ thanks!! no i can make a zaku of my own!
KungfuMustard's avatar
Thank you man, I was thinking Heavyarms, but decided on a Zaku first before anything, haha. XD This will definitely be of help!
eva-guy01's avatar
You're welcome! Hope I get to see its building progress!
KungfuMustard's avatar
I think I'd need a little help with building it. This would be my first to take on and I'm a stickler for it being of proper proportions and all.
eva-guy01's avatar
What kind of help do you need. This may pose a problem for you since this tutorial actually encourages trial and error. Everyone have different sizes and proportions so there is no exact science to this. But you can get the nearest proportion by doing the following:

- never use the exact measurement of your head. Always add at least 1 to 3 inches more. Better more than less.
- the rectangular curved part of the head where you attach the eye-shaped parts, the average size is 10 inches to 1 foot. If the measurement of the crown of your head (from forehead and then around the skull) is 17 to 20 inches, make the rectangle 10 inches. 21 to 25 inches, make rectangle 11 inches. Any larger make it 1 foot.
KungfuMustard's avatar
Thank you man, I appreciate it. If I ever get around to making a cosplay mobile suit I'll put up an image and give you a heads up.
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