Whether you’re a kid looking for a costume helmet or a parent who’s trying to keep the kids’ Halloween costumes safe, a helmet is essential. Especially if you’re a medieval cosplayer, it’s important to have a hat that looks like it could be worn by an actual knight.
First you’ll need to make a base form for your helmet. You can make this from a piece of cardboard. You’ll also need a small fake welding gun and coveralls. The template can be found on pages 4 and 8.
Next you’ll cut out the patterns for the inner helmet surface. You’ll need to take care to cut around the mouth and eye openings. You’ll also need to cut out the triangles on the front of the helmet.
You can then wrap the inner surface around the base form and glue the edges together with epoxy. After this is completed, you’ll be able to finish the helmet by cutting out the visor. At this point you can add ear details using a bench top belt sander.
Finally, you’ll need to use the spackling paste to fill in the dent in the back of your helmet. You’ll need to apply several applications to get the texture just right. You can then smooth out the other areas with the spackling paste.
Depending on how detailed your helmet is, you may need to do multiple applications of spackling paste. You can also smear the helmet with glue to seal the seams.