Stunt
The Stunt Helmet was the standard Stormtrooper helmet used during the production of Star Wars: Episode IV - A New Hope in 1976. Designed for the majority of on-screen appearances, it was worn by background performers and stunt actors throughout the film. Compared with the Hero Helmet, the Stunt Helmet was intended to be quicker to manufacture while retaining the distinctive appearance of the Imperial Stormtrooper.
Manufactured by Andrew Ainsworth at Shepperton Design Studios using vacuum forming techniques, the Stunt Helmet was assembled and hand finished using original production methods. It featured flat green eye lenses, a larger frown with additional teeth cut out for improved visibility and ventilation, and simplified hand-painted details. As with all original production helmets, each example displayed subtle variations in trimming, assembly and paintwork, making every helmet unique.
The Stunt Helmet became the most widely seen version of the Stormtrooper helmet in the original film and has since become one of the most recognisable costume props in cinema history. Its distinctive asymmetry and handcrafted construction have been extensively studied by prop historians and continue to define the authentic appearance of the original 1976 Stormtrooper.
HDPE
"Mind your head..."
The rush for Stormtrooper helmets and armour in time for the first shoot in Tunisia was met just in time by Andrew. For the hot, dusty conditions of the desert, the 27 ‘Sand Trooper’ helmets were made from HDPE ( High Density Polyethylene ). Although very tough, this material did not take paint easily and so the distressed format of the Sand Troopers fitted the bill perfectly Later models were made from better quality white ABS material which we still use today.
Reg-Brow
"Nice and airy in here..."
The regular height of the brow produced more room inside the helmet, this gave an easy fit and more suitable for action shots. In actual fact, because HDPE is difficult to mould and retain the formed shape, many of the Stunt Helmets had varying degrees of higher brows.
EAR PIECE
“BRIDGE THE GAP...”
The ear piece was developed to cover the join between the front and rear helmet mouldings.
They gave the helmet presence, like a lion's mane whilst simultaneously giving the impression of a communications device, by way of the raised vertical grid.
Flat Lens
"Which way now..."
The stunt men playing a Stormtrooper could not see well enough through the original ‘Blister Eyes’ and so Andrew replaced them with a flat green acetate for the action shots. Remember in ANH, one of the Stunt Stormtroopers hit his head on a doorframe, and that was with flat lenses, imagine the problems they would have had with blister eyes!
HAND PAINTED
“METICULOUS DETAIL...”
On the Stunt Helmet, meticulously hand-painted frown is extended to the edges of the frown, revealing 8 vent openings. Attention is also paid to the small details of the mouth and ears. Thin decals are utilised elsewhere on this edition (chevrons, cheeks and temples) avoiding the use of cheap, thick printed vinyl.
MIC TIPS
“FUTURISTIC COMMUNICATION...”
"The 'Hovi Mix Pa 2,' also known as Mic Tips, are now 3D printed, meticulously modelled from the original part. Initially, Andrew tried crafting the Mic Tips using vacuum-formed plastic, but they lacked the precision and sharpness he desired. Seeking a more straightforward solution, he visited his favourite greebles shop, the Wheelhouse in Hounslow. There, he stumbled upon an unusual sink cleaning attachment called the Swirlerator, marked with the part number 'Hovi Mix Pa 2.' It turned out to be perfect."