This was a fun carving to do. I used a couple of pictures of Vader's helmet and then carved it from a particularly thick-skinned pumpkin. You can tell a pumpkin is going to have a thick skin if it is really heavy to pick up.
This design took me a little over an hour to complete using my giant assortment of power tools.
When I am not carving pumpkins, I run a bulletproof vest company. BulletSafe Bulletproof Vests are the value leader in body armor. We are very popular with people like armored car operators and ATM repairmen.