How to Make a Helmet Cover

Fabric helmet covers can be sewn in under an hour.

Helmets, such as Kevlar, hunting or collectible helmets, can be easily covered with cotton or waterproof fabric to protect the outer surface or to change the color scheme. Use camouflage fabric for military or hunting helmets. Youngsters enjoy playing Army with assorted helmets and a helmet cover can allow the pretend play to feel more realistic. This fabric helmet cover will fit medium- to large-sized helmets, and may fit some brands of extra-large standard helmets. Medium to large helmets fit 22 1/2 inches to 23 1/2 inches head circumference. This cover will not fit helmets with extended ear protection or face masks.

Things You'll Need

• 25-inch diameter cotton or waterproof fabric circle
• Washing machine
• Clothes dryer
• Pins
• Elastic, ¼-inches width by 20-inches length
• Sewing machine
• Thread
• Straight pins
• Scissors
• 2 small safety pins

Instructions

1. Wash the fabric circle in the wash machine following the care instructions for your fabric. Dry the fabric in the dryer. You want to pre-shrink your fabric before you sew the cover so the cover doesn't shrink and no longer fit when you wash it in the future.

2. Fold the edges of the fabric circle (shrinkage will vary, but fabric allowance here allows for an inch of shrinkage) over ¼ inch against the wrong side of the fabric and pin the edges.

3. Sew the pinned edges using a zigzag stitch and ¼-inch seam allowance. Remove pins.

4. Fold the hemmed edge over 1/2 inch against the wrong side of the fabric. Pin. Leave a 2-inch opening that won't be sewn or pinned (to allow elastic to feed into casing).

5. Sew, using a ½-inch seam allowance and a straight stitch, along the pinned edges, forming a casing. A casing is a "tunnel" where elastic or a drawstring is fed. Don't sew the 2-inch opening closed. Remove pins.

6. Pin a safety pin through one end of the elastic. Pin a safety pin through the other elastic end and through the fabric of the opening. Feed the safety pin/elastic through one side of the casing opening until it emerges from the opposite side of the opening. Pull elastic ends together and hold. Remove safety pins.

7. Place the two elastic ends being held together beneath the pressure foot of the sewing machine. Sew using a straight stitch about ¼ inch from the elastic ends, back and forth, until the elastic ends are securely connected. Release elastic. The elastic will tighten the casing.

8. Spread the fabric of the 2-inch opening smooth and sew the opening closed with a straight stitch and ½-inch seam allowance. Reverse your stitches on the machine to secure the stitching.

9. Stretch the helmet cover over the helmet, allowing the elastic to fit snugly beneath the helmet or helmet rim.

Tips & Warnings

• Wash and dry the helmet cover according to the fabric care instructions.

• Never add a cover to a bicycle helmet or a helmet needing to meet regulations of a sport or military branch.

• Adding a cover to a sporting helmet could increase the chance of helmet injury if the cover catches on something.

References

• Bullet Proof Me Body Armor: Helmet Measurements

Resources

• Gentex Corp Museum: US Army Helmet Exhibit