The TIE Pilot Costume: Lenses

Comparison of Flat Lenses to Bubble Lenses

Distortions caused by the curvature of the lenses are indicated by the blue arrows in the photo below. The placement of the lenses within the helmet causes most wearers to actually look through the thinnest part of the lens (noted by the orange circle) where the two curved edges converge and thus producing maximum distortion.

Flat lenses do not cause this distortion and are frequently preferred by costumers. Although the flats are not movie-accurate, they are safer and more convenient for hours of trooping at a time!

The lenses are dark enough to where the wearer's eyes cannot be seen from the outside, but the wearer can see perfectly. The lenses, whether bubbled or flat, are like wearing sunglasses.

Acquiring or Making Flat Lenses

Premade lenses can sometimes be found on eBay but can be pricey. To make your own lenses, you will need a Shade 5 welder's faceshield and the flat lens template.

Download the lens template, print it, cut it out and trace the shape onto the welder's shield (note that the lens should be about just over 4¾" wide so please compensate appropriately for various printer models). The plastic should be thin enough to cut with scissors. Make sure to cut larger than the traced line, and carefully trim in small increments -- it's better to have too much material left than not enough!

Installing the Lenses

Using gloves or some other hot-material handling method, grasp the lens by the edge and transfer it into the eye hole of the helmet. Let it form into shape and them apply hot-glue to adhere. The material will take a significant amount of time to cool, so do one lens at a time.