For my son's twelfth birthday I decided to attempt a Homemade Darth Vader Birthday Cake. I got some tips off the internet and started. I decided to make it in two halves (top and bottom). For the first half I used heavy duty solder wire and made a 3D frame that would serve as the back of DV's head, then cover the frame with triple layers of heavy duty foil.
Second, using a cheap Darth Vader helmet, I took triple layers of foil and pressed it into the helmet to make the shape of the face, then I made a wire rim just to ensure it kept its shape in the oven.
Next I made double batch of Madeira Cake, filled the homemade cake tins and baked. Unfortunately the Madeira cake was to heavy for the bottom half, once it came out it broke apart, so I had to change the cake to a 2D (disappointing) but I continued. The face (top) came perfect, baked a full 2 hours but looked great (success).
Next I put cling (plastic) wrap in the helmet and moulded black sugarpaste icing into it and froze for about 2 hrs. After jamming the surface of the cake, I transferred the icing over to the cake, I used whatever tools (spoons, forks, etc) available to mould the eyes nose and mouth being very careful not to tear the sugarpaste icing, edible silver paint for the grill, black butter icing to fill gaps and that (at least to my son) is the coolest Darth Vader Cake.
I made this Darth Vader Birthday Cake for my husband's friend from work. This was my first time ever using fondant. I started by making 2- 6" cake circles, a square cake, and a cake made from a Pyrex bowl. I stacked the 2 6" circles and round bowl cake. Then I crumb coated the stacked cake. I cut the corner off of the square cake and frosted it to the front of the cake to make the mouth piece.
I decided to make my own fondant because the store bought kind was to expensive. I used the marshmallow recipe from the Wilton website. It was super easy. You melt 16oz of mini marshmallows and 2 tablespoons of water in the microwave. Then I added the black dye to the bowl so it would mix in better. You add 3/4 of a pound sifted powdered sugar and fold it in. Using vegetable shortening to grease your hands and counter and kneed to form dough. I put it in the fridge overnight to set.
Then using a rolling pin I rolled it out. When I was placing it on the cake a made creases and flaps in the back to form the neck covering of the helmet. For the eyes I used fondant and molded them using a large spoon. I made the crease at the top by rolling out fondant and using a pizza cutter to cut straight lines.
For the mouth piece I pipped on silver glitter gel. It turned out pretty cool and he loved.