New to this, question about helmets.

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Jcq126

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Hey guys, completely and utterly new to all of this crafting stuff but am highly interested in it all. I know that you guys tend to use a lot of EVA foam, fiberglass, liquid plastic, clay etc all when building armor suits, helmets etc... but my question is has anyone ever built an actual protective helmet? Say instead of just building a replica of a hero helmet you like, pretend that you were actually building a real helmet for a real hero, something that needed to be fitted, light weight yes durable? Has anyone ever tackled something like this?

My ultimate goal is to build an actual protective helmet that will fit my head and offer real protection and something that isn't just for show, I was thinking of learning how they make motorcycle helmets and then go that route, but instead make it not as bulky and custom fitted to my head and then design it myself?

Does anyone have any tips of how to go about making a REAL defensive helmet? rather than something just made from clay? Something that is light enough weight yet actually protective and wearable like a motorcycle helmet that can be fitted like an Iron Man size helmet?
 
The problem with making "something like a motorcycle helmet but not as bulky" is that the "bulk" is what makes it protective. It adds enough material around the head to absorb and dissipate impact. A fitted helmet can't do that, it's basic physics.

For safety sake, I would advise against this, but I need to know why are you so intent on having a functional helmet? I just can't imagine a use for such an item.

-Nick
 
Similar topics to this come up from time to time, and and Nick says it doesn't really make a lot of sense not only functionally and physically, but also cost effectively. Although, striving for something that will offer protection from rain would be kind of cool.
 
Everybody, my self included, when they first start seeing the things that the artisans on the RPF make and incredible movie creations, thinks, man, I could make a real light saber, or a suit of armor like a comic book hero that would really work, or whatever...

The sad fact is that there is a lot of work, science and research required to make a real world weapon / defense item that exceeds what you can buy at the gun shop, humans have been working on better ways to kill each other and defend themselves for thousands of years, you aren't gonna luck into a flying, bullet proof, ultra range hyper laser that can incenerate people from space on a message board for 38 bucks in S-Mart dollars.

If you want to make a superlatively cool, well crafted piece that looks like dream Uber armor, you'll find people here that can illustrate the skills necessary to make such a thing. You will also find people who can direct you to the experts in real work weapon/armor systems, but sadly, it's highly unlikely you are going to find the magic bullet for the world's ultimate weapon / defense system.
 
Oh this was blown up accidentally by my poor wording possibly. I don't mean some uber type of realistic helmet that can be sold to the government because it is so indestructable and protective. It doesn't have to actually be PROTECTIVE as in to withstand baseball bats to the head or anything lol but I mean something that won't melt in the rain, or be cracked by smacking my head lightly. Just something that can hold up like a bicycle or motorcycle helmet would, but I want it fitted around my face/head and to have it look like a real super hero helmet. I know I can build something that can LOOK the part, but I actually want something that can look cool and actually withstand banging my head on something lightly etc.. I know this sounds stupid but i'm serious and am not looking for someone to construct this for me but more just if anyone has any ideas what would be the best to make this out of? something like BMX helmet material but for covering the face and head.

Apologies if this is confusing and a stupid topic, but really I figured this is the best place to come.
 
I was thinking about something similar myself. Not so much about making a helmet from scratch, but more along the lines of making custom helmet shrouds, that maybe I'd make and sell for folks to place over their DOT rated motorcycle helmet. Then I mentioned the idea to one of my lawyer friends (I know about half the assistant state attorneys in the Tampa area), and they pointed out that modifying a DOT rated helmet in any way revokes the DOT rating, thus making it illegal, and also opening myself up to lawsuits that would crop up.
I'm currently in the process of making a replica of the N7 helmet from Mass Effect 2, and I'm quite sure once I get the mold set up and pull a resin copy, it would be sturdy enough to withstand getting rained on, or facepalming myself, maybe even my tripping and smacking my head against something...but it's definitely not something I'd wear mountain biking or on a motorcycle.
The way the DOT rated helmets are designed are to minimize the amount of damage to your head, and they always have to be replaced afterwards, because they are meant to deform and break to absorb as much of the shock as possible.
 
Patrolling??

Patrolling what? Police patrol, and they have gear for that. They do it, so you don't have to.
 
I'm sticking with my original assessment: if you want something that will protect you to ANY degree, you are barking up the wrong tree. The people here will be able to tell you how to make a helmet that looks like it was forged in the heart of mount Olympus. They can make a helmet look like it's made of an old meteorite. They can even make a helmet LOOK like it'll protect your noggin, but when it comes down to it, when you start trying to make protectionary gear to stand up to the standards of a industry-regulated product like a motorcycle helmet, you're taking your life in your own hands. And I feel it's irresponsible not only for people to help you along this route, but for you to ask people to help you on this.

If you want something that won't melt in the rain or something that won't scratch and ding if you drop it, fine, we can recommend methods and materials to do that, but if you're talking about something that won't ding your head if you're dropped while wearing it, you're out of luck. Props are about the appearance of function, not actual function.

You say you want something that can take a light smack to the head "like a motorcycle helmet." What sort of smack are we talking about, considering that motorcycle helmets can take quite considerable "light smacks?" What exactly are you planning on doing on these "patrols," and who are you patrolling with/for?

This whole thing just seems like a can of worms. If you've worded yourself poorly, by all means set the record straight, but as it stands it seems you want to build safety gear...which is counter to the purpose of safety gear.

If you need safety gear: buy it! There's a reason those companies spend MILLIONS on research, development, and testing. It's necessary.

-Nick
 
heres my thing, helmets have served man well before the invention of DOT. one might use leather padding or thin impact foam to soften blows to the head, but most of the time, metal is the way to go, usually smithed steel.to start, i would cast your head for a workable model to custom fit.

after the head is made, take quarter to half inch thick strips of impact foam, or soft leather in layers to equal the right thickness, and position them on the head, heat shaping the foam and watershaping the leather. these should be equally spread out in a star pattern (*) moving from the very top of the head outward.

once this is done, connect them all on the outside with thin sheet metal so you get a star shaped metal piece with strips of leather under it.

once this is done, you must make a hammered steel helmet to match the profile of the padding, which in turn you've made to match the contours of your head. either that, or you can make a fiberglass shroud, which will probably bust on the first hit or so, but you'll likely be fine.

after its constructed, get someone to do a few test hits and see how it feels. this is about all they had in the old days during war, so if your out for some rough and tumble, it'll suit ya just fine.
 
brimst0ne13 said:
after its constructed, get someone to do a few test hits and see how it feels. this is about all they had in the old days during war, so if your out for some rough and tumble, it'll suit ya just fine.
Click to expand...

Ladies and Gentlemen, we have our liability suit waiting to happen!

"Yes your honor the man from the internet told me to get someone to hit me in my helmet that he told me how to make...he said I would be just fine."

I'm going to continue saying I don't think it's wise to advise someone on something like this on a PROP forum unless we have all the details...and most likely then it will be best not to continue.

There are very real safety and liability issues here. Let's just all wait and let Jcq126 explain EXACTLY what he wants to use such a helmet for, and why a traditional, tested/regulated helmet won't fit the bill before giving him any ideas.

-Nick
 
I'm curious about the Night Patrolling thing. I may have to link this thread to Mark Millar, LoL.

Anywho, you probably want to look at working on vac-formed carbon fiber.
 
Jcq126, first, welcome to the forum. But let me say that this is a hobby forum.

So this is actually NOT the best place to go to if you want to create protective armour of any kind.

Since you are not looking for a specific, movie, comics, game genre related design, I advise you to go and look for readily available protective gear, primarily for safety and health reasons.

Modifying such gear to look the way you want it to, and in doing so keeping it´s protective properties, will sure be the best way to go.

We had a very similar thread in the past go way south ("advacned action suit", anyone?), the topic is quite a bit off topic and the OP does not have access to the OT forum for a bit, I will close this thread.

Regards,
Michael
RPF staff
 
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