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.