EPISODE VI: RETURN OF THE JEDI
Luke'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 three snaps on each side reinforced by black leather. The model info here is from the helmet pictured below with four snaps it is unknown if each variation of the helmet has a different order number. It is also not known for sure what size helmet he wore, though the extra large was probably the most used.
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 Luke and Leia had them. They were white and then dyed camoflage.
The belt is 2" wide black leather with a rectangular buckle, D-ring and lightsaber clip.
Luke is wearing East German officer riding boots with the smooth dress finish.