First I’d like to say thanks to all the people who gave their ideas on this site. I made this Darth Vader birthday cake after looking at your lovely cakes for my son Jake on his 6th birthday.
I borrowed his Darth Vader helmet and placed 3 layers of tin foil over it to make my mold. I placed the cake mold in a roasting tin supporting it with crunched up tin foil. I then poured a Madeira sponge mixture in and baked it for about 4 to 5 hours. It took ages because the mold was so deep.
Arranged the cake on a board, sliced through the middle and added butter cream icing. Then proceeded to add any missing detail to the face using fondant icing. Covered the whole face using black fondant icing and used various sugar crafting tools to sharpen the detail. Using edible silver powder and vodka painted in the nose piece and also used it to give the eye area more definition. Molded the knobs for the mouth piece and used cocktail sticks to attach to cake then painted silver. I cut a potato into a triangle shape and cut out the mesh work to be used as a stamp on the lower mouth piece. This was the only way I could think of to get the mesh detail.
Anyway, I think it turned out well and it was a big hit with my son, which is what mattered.
Related cakes:
Cool Homemade Darth Vader Cake for Star Wars Theme Party 
Coolest Darth Vader Birthday Cake 
Cool Homemade Darth Vader Cake 
Cool Homemade Darth Vader Cake Design 
Fireman Sam vs. Darth Vader – A Mixed Up Cake for an Indecisive 4-Year-Old! 
Coolest Darth Vader Helmet Cake 
Awesome Homemade 3D Darth Vader Helmet Birthday Cake 
Cool Homemade 3D Darth Maul Birthday Cake
This is awesome! The design is very clean. I am impressed with how you made the cake mold. Did you have any problems with it collapsing? Well Done!
Thanks for the kind comments. I used the extra thick tin foil and it took me a couple of tries to get the mold into a stable position. I scrunched up loads of foil and pushed my mold into that while the helmet was still in it. Once it was stable I took the helmet out. The mold held its shape really well and the only problem I had was when I was trying to remove the cake as it stuck in some places.
I was really pleased with how it worked and will use the tin foil again much cheaper than a cake tin.
Anyway good luck to you if you give it a go.
Once again thanks.
Michelle C
awesome cake! can you please email me a video or some sort of visual instruction (pictures) on how to make the mold. I kinda got the picture but don’t want to mess it up. thanks. it’s for my son’s 9th birthday. azcatering@yahoo.com
Hi Lin
I’m really sorry but I only took photos of the end product. The helmet I used was from a rubies child’s fancy dress costume. Tescos do the really thick tin foil and when you cover the helmet I found using a large clean paint brush helped to get the foil into all the nooks and crannies. I hope this helps and good luck with yours. Just a reminder because the helmet was so deep the cake just took hours and hours to cook. I cant remember exactly it must have been at least 3 though.
kind regards
Michelle
PS i will take photo records of my future cakes
I love your cake! I am making my grandson 1 for his birthday. What temperature did you bake the cake at? Thanks!
That is so clever! The cake looks fantastic and I love the way you’ve made the mould. I’m not sure I have the skills, time and patience to do it the same way but it’s very inspiring!
ok this may seem obvious….
did you leave the plastic helmet under the foil for baking? or did you remove it and just use the foil form?
Hi no I had to remove the plastic,
you just use the foil shape you created and prop it up with other pieces of scrunched foil.