How to Make a Cosplay Helmet

Fans of cosplay gather at conventions around the world.

Costume play, also known as cosplay, got its start as part of an artistic subculture in Japan. This growing form of performance art allows fans of science fiction and fantasy movies, video games and comics to become a part of those fantasy worlds by dressing up as their favorite characters. For many cosplay fans, their costumes are not complete without customized helmets. Cosplay helmets can be made of a variety of materials and be as simple or as elaborate as you choose.

Things You'll Need

• Design template
• Scissors
• Tape
• Thin cardboard
• Balloon
• Hot glue gun
• Newspaper
• 2 cups of water
• 2 cups of flour
• 1 tbsp. salt
• Spray paint

Instructions

1. Sketch the design of your helmet on paper or print out a premade template from the Internet. The template should break up the design of the helmet into large pieces you can use to build your helmet.

2. Transfer the shapes to cardboard by gluing them, then cut out the shapes. Bend the pieces of cardboard to make them more pliable.

3. Blow up a balloon to about the size of your head. Place the balloon in the center of the cardboard shapes as you tape the strips around the balloon to form a mask. Apply hot glue to the cracks between the pieces and remove the balloon.

4. Create papier-mache by dipping strips of newspaper into a batter of flour, water and salt. Apply the wet strips to the helmet to create a hard shell. Overlap the strips for a sturdier shell. Let the helmet dry overnight. Repeat this process to give the helmet three to four coats of batter.

5. Paint over the shell using spray paint. Let the paint dry and apply additional coats until completely covered. Add finishing touches, such as decorative lines or a chinstrap.

References

• Cosplay House: What Is Cosplay?
• Cosplay.com; Cosplay Tutorials; The Basics of Cardboard Helmets
• Storm the Castle: How to Make a Spartan Helmet out of Cardboard and Papier Mache