I received a couple of inquiries about exactly how I make my cosplay Knights Templar / Crusader / Great Helm helmet out of old discarded Coroplast® real estate or election signs. Since it was raining this weekend I figured I would make one and photograph the process. If you read through these instructions and have any specific questions please let me know.
|This is intended to be a rough guide on how to make a Templar Helmet from old plastic. The measurements shown are the ones I used for this build. You will have to adjust things for your project.
Keep in mind that I figure this stuff out as I go, and kind of wing it. In the back of my mind I know things that are too long, or short, or crooked, can always be cleaned up/fixed later. If not then I can always start again.
Remember you are creating something cool out of other people's trash.... Have fun with it.
(from mini golf), utility knife/box cutter, and a ruler. For this project you also need some masking tape, large and small drill bits, paper fasteners, and a little paper towel. Everything you need is really simple, and very inexpensive.
Dr. Bunsen Honeydew, maybe yours is shaped like Beaker.
On the side of the plastic you want on the interior of the helmet, cut down each of the rows from top to bottom so the pieces can be curved. Leave five, or so, rows at each end of each piece uncut. This will help flatten out the sides of the helmet. Charlie brown is the only one I know with a round head, so a little flat on the sides is important.
We have four pieces that are 7" x 5". On each piece measure 1" from the top down, in the middle. Measure 1" up at both ends. Using a plate, serving plater, or just guess, mark curves to the spots you measured as shown above. It should look like a sagging bridge when you are done.
Just like with the bottom, cut down each row on what will be the inside of the helmet. Cut down through all the rows this time, there aren't any flat spots.
Once the cuts are made glue the four pieces end to end. Make sure one end is open and it looks like a big crooked 'C' when you are done.
skin 6 reinforcement tabs, 1" x 3". These will help hold the top and bottom in place securely when you start assembly, plus they are used to mark the eye holes.
Next, glue the tabs into the bottom portion of the helmet. Add one front, back, each side, and on the outside of the eye holes. Put the tabs in the center of the seams and keep them straight. On top of adding support to the project they will help you keep things lined up.
adhesion promoter when painting onto a flexible plastic. It is what body shops do before painting a plastic bumper. It made a world of difference and I highly recommend its use.
weathering. If you are interested there are lots of posts, and videos, from people considerably more talented, and experienced at weathering. For our project I just use cheap, acrylic, black paint I picked up at Walmart.
Please check out our other sites - HalifaxSportsPhotos.caTippinators.comCoroplastCreations.com
|Let me know if you have any questions|
|Photos courtesy of |