How to Make a Helmet Using a Construction Hat

You can use a construction hat to make a simple helmet.

The helmet is a protective covering for the head of a warrior going into battle. A homemade helmet can give your costume for a medieval warrior, knight, or historical or science fiction character the finishing touch it needs. You can use a real or toy construction hat (hard hat) to create a helmet for a costume or to use as a decorative piece.

Things You'll Need

• Photo of helmet
• Construction hat with suspension
• Plastic or fiber cording
• Glue
• Marker
• Silver or gray spray paint
• Black acrylic paint
• Sponge brush
• Rag

Instructions

1. Clean the construction hat to remove oil or dirt. Remove any stickers from the surface of the hat. Adjust the standard or ratchet suspension to fit the person who will be wearing the helmet.

2. Refer to a photo of the type of helmet that you want to create. Glue cording to the construction hat to create ridges or a crest pattern. You can draw a more intricate pattern onto the hat with a marker for a gluing guide. Allow the glue to dry for 24 hours.

3. Spray-paint the outside of the helmet with one to three light coats of silver or dull gray paint in a well-ventilated area. The gray mimics the color of a metal helmet.

4. Coat a small area of the helmet with black acrylic paint using a sponge brush.

5. Rub some of the black paint from the helmet with a rag. The remaining paint will give the helmet a used appearance. It will sink into any nicks on the hat. It will also emphasize the cording.

Tips & Warnings

• Enhance the helmet with a plume. Add a filet crochet mesh piece to the back of the helmet as a reproduction of wire mesh for neck protection.

• If you want the helmet to look as though it has been in battle, add a few nicks and scratches before painting the surface.

References

• All About Head Protection: How Hard Hats Protect You
• The Art of Tom Banwell; Making a Dragoon Helmet; Tom Banwell; 2008
• Swords and Armor: Medieval Helmets and Battle Helms