The helmet made for this tutorial won TechShop Austin's Best of Metal 2013 competition!
In this tutorial we will make an authentic Viking helmet (Spangenhelm) using the Basic Helmet Frame
as the base. After finishing the steps in that tutorial, return here and we will finish the helmet in the style of a 6th century Viking. We will be cutting and shaping the dome plates, riveting the piece together, and adding padding.
If you want to use your helmet in SCA combat, you'll need to follow the SCA Marchall's Handbook
in the design. In particular, you need to make the frame and dome from 0.06" thick metal (brass and stainless steel) as both the strength and mass of the metal are what protect your head from blows (i.e. don't make it from aluminum, titanium, or other ultra light materials). In addition, SCA combat regulation specifies that your rivets are no more than 2.5" apart and your padding needs to be a minumum of 0.5" thick of closed cell foam padding. In order to make the helmet SCA combat regulation, you'll also (eventually) need to make a face mask, but we won't be creating a face mask in this tutorial.
I made it in TechShop
. You'll need to take the MTL103: Basic Metal Shop SBU and MTL201: Sheet Metal - Organic Shapes SBU classes in order to be qualified to use the tools in the TechShop for this piece. The best thing about TechShop: there's a Lowes right in the shop! If you need more supplies, you don't need to drive 45 minutes to the hardware store, you don't even need to step out into the rain.
Tools I used:
- Electric drill
- Cobalt or titanium drill bit (sizes 9/64" and 1/8")
- Beverly shear (or you can use a hand shear)
- Electric grinder or sander
- Buffer and buffing compound (white is fine for both the stainless steel and brass)
- Armoring swage (or you can use a leather sand bag)
- Plastic (polyethylene) mallet
- Riveting gun
- Measuring tape
Materials I used:
- 0.06" thick brass sheet metal (type 260), cut from about 6 inch by 6 inch section. (However, you can use mild steel, stainless steel, or aluminum instead)
- 0.06" thick stainless steel sheet metal (type 304) about 1 foot by 2 feet (However, you can use brass, mild steel, or aluminum)
- (12) screws (#6-32)
- (12) wing nuts (#6-32)
- a box of rivets (1/8" diameter by 1/8" long)
- another box of rivets (1/8" diameter by 1/4" long)
- a few more rivets (1/8" diameter by 1/2" long)
- some rivet washers, if needed (1/8" diameter)
- 1/2" closed foam padding, about 2 foot by 2 foot
- Beacon's Quick Grip adhesive (or some other glue to attach the padding to the inside of the helmet)
- some card stock or manilla folders to cut out your template (about 2.5 feet by 1 foot)