EPISODE VI: RETURN OF THE JEDI
Leia's Endor helmet was made from a WWII pilot summer flight helmet model AN-H-15. There are different variations of the helmet, but this particular one had four snaps on each side reinforced by black leather. It's not known for sure what size helmet she wore, but it was probably an extra large since they fit tight and she had her hair braided up in it. The exact model info for the type used is as follows:
Order No. 44-6446-AF
St. No. 8300-401500
BATES SHOE CO.
ARMY AIR FORCES
The AN-H-15 helmet shown above has had the small visor or bill removed from the front. On the Endor soldier helmets in the movie this visor was actually cut off, leaving about a 1/4" of it and the frayed edge. This was done because it would hang too low on the face, covering the forehead. The three leather straps along the back, originally used to keep the receiver cords back, were removed. On the right side of the helmet a brass hook (seen above), that was snapped on, has been removed. The hook was for attaching the face mask. The receivers (headphones) were not used. Black foam padding was used to plug the receiver holes. Two leather flaps were added just below the black receiver padding. Quilted ridges were sewn in a strip to the top of the flight helmet.
Around the helmet a custom vacuformed plastic "donut" shape was placed. It was painted olive drab with other details and weathering. A hard (possibly plastic) visor was attached just under the front of this plastic ring, it was covered in the same matching tan fabric used for the quilted ridges on top.
The design for the Endor helmets came from Nilo Rodis-Jamero : "I used to go to a
surplus store, and I had seen a lot of helmets that were made out of cloth. So I bought
some of them and adapted them to a new original design." -From Star Wars The
Annotated Screenplays by Laurent Bouzereau, published by Del Rey.
Available from the official Star Wars site at mosespa.com
The ponchos were most likely custom made since only Leia and Luke had them. They were white and then dyed camoflage.
DDC Defender Sporting Blaster