How to Make an Ancient Roman Helmet
It is fun to make Roman helmets with cardboard or paper. But it is more challenging to make something a little more authentic, using bronze casting and perhaps adding a plume or crest. The Romans used metal, usually bronze, to make their helmets. With helmets of metal the heads of the Roman soldiers were well-protected when they fought the Carthaginians and other enemies. Helmets styles varied over the centuries.
Things You'll Need
- Scraps of bronze
- Home foundry
- Wax
- Clay
- Woolen or linen cloth
- Glue
- leather
- Horse hair
- Goose feathers
Instructions
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Preliminary Preparations
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1
Study Roman helmets. Consult pictures on the internet.
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2
Choose the style of Roman helmet that you wish to make. Ancient Rome lasted more than 1,000 years. Early helmets of the so-called Montefortino type were more highly decorated at first, but gradually became simpler in form. These late Montefortino types are easiest to make. The subsequent Coolus and Imperial type Roman helmets are more complex.
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3
Decide what material you wish to use in making the helmet. The popular cardboard Roman helmets are fun to make. But try to be a little more authentic. Choose some metal as your material. Bronze is preferable.
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4
Set up a home foundry in your back yard. You can obtain information about the necessary materials with instructions for setting it up online.
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Try to find a genuine Montefortino helmet. Look for it in museums. Ask professors of ancient history if they know where to find one. If this involves too much travel, study pictures of this kind of helmet on the internet.
Casting the Helmet
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Make a wax model of the helmet. If it does not turn out well the first time, try again until you create a good model
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7
Encase the wax model in clay, Leave an opening at the bottom of the clay model.
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8
Heat the clay until all the wax runs out the hole at the bottom, and the clay is hard. Use your home foundry if it is capable of providing a moderate source of heat. Otherwise use a stove. Then let it cool.
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9
Turn the clay model upside down and place it so that the hole at the bottom fits into the gate of your home foundry.The gate is the end of its delivery system.
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10
Heat bronze scraps in the furnace of your home foundry. When the metal melts, use the foundry’s delivery system to pour the molten bronze into the cavity in which the wax model used to be.
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When completely cool, remove the clay, so that the cast of the Montefortino Roman helmet will appear. If the results were not good, repeat the procedure until you succeed. Improper cooling may cause irregularities. Also remember that metal contracts as it cools. Adjust the size of your helmet to allow for this.
The Finishing Touches
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Line the interior of your helmet with a woolen or linen lining. Use glue to attach the lining. This will protect the wearer’s head.
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13
Design and make two leather flaps. Attach one on each side of the helmet in such a way that they will protect the soldier who wears it. Use your imagination in designing the flaps.
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14
Design and make a plume to be attached to the knob on top of your helmet. If you want to be authentic, attach horse hair or goose feathers to a wooden holder designed to fit on the knob of your helmet. Instead of a plume, you may design a horizontal or vertical crest using pictures shown on the internet as your model. There is evidence that Roman soldiers used plumes only for processions and removed them when fighting.
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Try it on see if it fits. If not, give it to a friend with a different head size or keep it as a curiosity piece.
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Tips & Warnings
If a bronze helmet is too difficult for you, instructions for making a cardboard facsimile are available online.
The method of casting the helmet is the lost wax method used in ancient times. The home foundry is suggested as a convenient heat source and delivery system. If not compatible with your home foundry, make the necessary modifications.
