Most of you have seen some of the super cool batman helmets for motorcyclists (Inspiration: Batman helmet - Helmet dawg), which look super sharp yet are quite expensive. Moreover for europeans shipping costs for such baby would equal to almost full price of the helmet itself, thus why not to make one on your own?

This instructable will guide you step by step on material needed to produce road worthy and aerodynamic batman helmet from scratch. You don't even need advanced skills, studio or proper workshop to make this one happen.

What you will need (or anything along the lines, I tried to make this on a strict budget in case experiment happens to be fruitless):

  • Black full face motorcycle helmet (if EU it has to have a standard sticker on the back of it to be road worthy). Used: Shox fullface helmet for around £30
  • Tinted visor. Used: Shox for around £12
  • Bat 'ears' - parts of moto helmet kit which we will customise to fit the helmet shape later. You can 3D print these or buy sharp pieces of plastic and simply cut it out. Used: Motorcycle helmet fin kits for around £ 5 each (ebay it)
  • Matte or any other colour paint. Used Plastikote for around £9
  • Exacto knife, super sharp scissors or related cutting instruments
  • Super glue
  • Sanding paper
  • Tape to prevent paint leaks
  • Batman decals/stickers. These can be found anywhere for £1-2 each
  • Bottle of flammable substance or general intoxication

Time: around 4-5 hours in total (two weekends)

Step 1: Preparation

Prepare the helmet base itself. That includes taking off all the decals, making sure visor is detached to avoid any scratchings etc. In my particular case helmet came with printed on marks and not simple stickers/decals, which left me with only option of sanding it off.

This is freaking awesome dude, nice instructable!!!
It looks great, but I have a concern if you plan on using this as a road helmet. You mentioned there were glue burns. If I understand you correctly then the glue has melted some of the plastic. This implies that the structure of the helmet has been changed (possibly damaged) where the glue was applied. Then additional objects have been placed on potential weak spots. I'd find a helmet made of fibreglass or find a different adhesive for the fins.
<p>This is a very good point being raised and I guess people should be very cautious and aware of it. In this particular case the 'burn' was purely cosmetic, basically the glue just left the raised trail which had to be scraped off and sanded to smoothen it, it didn't compromise the structure. </p>

About This Instructable




Bio: Digital ninja by day, DIY junky by night. Basically I get drunk and then make random sometimes useful stuff.
More by alech:Batman motorcycle helmet (aerodynamic as f***) 
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