Fallout 3- Brotherhood of Steel Helmet

In this tutorial, I will show you how to create a helmet based on the Brotherhood of Steel from Fallout 3. 
The finished helmet is comprised of a main body and a series of numerous attached accessories.
This guide will take you through the process of:

1. Planning
2. Helmet Modeling
3. Helmet Molding
4. Helmet Casting
5. Accessories
6. Painting
7. Assembly
8. Recycling your silicone

Please note that the Materials and Tools listed at the beginning of each chapter will only pertain to that particular phase of the project.  Keep this in mind as you budget your expenses since this can become very expensive if you buy too much at once.

Step 1: Chapter 1- Planning- 1: Measurements

Tools and Materials

• Pen & Paper
• Ruler
• Pepakura Designer

OPTIONAL

• Fallout 3 (PC) w/ G.E.C.K.
• NifSkope
• 3D software package of choice *

* I used 3DStudio Max 2010 (which can be expensive) but there are cheaper and even free software options like Blender

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

To begin, you are going to need to know how big your head is. 
Get a friend with a ruler to measure your general dimensions.
You will want to add about half of an inch to each side to allow for some padding and space. 

Comments

[Xlanar]

I really like your design, but since I am on a mac, I have no way to acces the Pepakura PDO file you provided. Is there a way to convert it on a mac or are you able to upload a PDF version?

Anyway, keep up the good work.

[agm88]

dude
freakin awsome

[awsomo-2000]

can i just buy one from you?

[elizabethp29]

Wow! Some day, I'm going to make this and never take it off.

[fretted]

bos_helmet.pdo

this is all i get it won't download like the file is gone !

[poofrabbit]

Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!

[TygrFr3d]

I absolutely love this mask! It's incredible how much detail you put into this.

[oliver520]

Great Job, were you planning on ever seling one of these??

[frankiboi89]

Ok Thanks. Like i said my helmet paper model is too flimsy and i guess i wont be able to do something with it. Its not looking like your model mine is more round. =/

[frankiboi89]

what thickness of card stock did you use because i used a card stock that was too thin and now i have to re-do all the paper helmet model.

Thanks,

P.S.: Nice instructable :p

[Josh Jay]

I'm not sure which brand of card stock it was. I went to Fed Office/Kinkos and picked out a card stock from the selection they had the counter.

[azreen]

Hi Josh,
It is Realllllllllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyy
ROCKINGGGGGGGGGGGGGGG G G G G GG G G

great job done man.

[aokona]

Pretty awesome all we need now is a field to play LARP with.

[Jayjlow]

Hey Josh! Your helmet is bad ass!! I wanted to take a look at the pepakura file so I can make a helmet for myself, but your link for the file is not working. I already took "dot" out of the URL but 4share.com is saying that the link is invalid or that "The file has been deleted because it was violating our Terms of user
Read more at." Can you upload the file to another source? like dropbox or something of that nature? THANKS!

[Josh Jay]

Would it be better if I just email it to you later tonight when I get home from work?
You can send me a message at Instructables with your address.

[Sarel_Sarel]

You are a genius!

[JoeMurphy]

great work. I don't make props, but this made me add it to my to do list!

[polerix]

Amazing work and great tips! I don't game but iconic props like this are pure geek gold. Incredible details, and you kept me guessing about the fallout grunge until the end. Great! 10/10 would shoot at first sight again!

[IconSpring611]

Josh,
I have never seen anything this impressive! The Force is obviously with you and you have many talents. Congratulations!

[Josh Jay]

Fallout is probably my favorite universe in all of gaming so I really wanted to get this one right. Thanks again!

[crispycat]

awesome tip! hope you win the contest!
+1vote

[Josh Jay]

Thank You! That technique has saved me hundreds of dollars in the last 3 years.

[tech dawg]

one question.....how long did it take you to right this ible' ?

[Josh Jay]

It took about 2 weeks in all. I already had a ton of documentation on Facebook that was more note-like in form. I had to rewrite it all into something more of an instructive narrative and make all of the diagrams in Photoshop.

[tech dawg]

wow thats a lot of work i congratulate you for being able to do something like this fantastic job!

[Josh Jay]

haha, thank you! I really wanted that Ms Pac Man table ;)

[MongooseDundee]

Outstanding!

[breumer]

Congratulations!

[CitizenSnips]

Congratulations with winning the grand prize!!!!

[Josh Jay]

Thank you for the votes and support!!!!!

[Lorddrake]

amazing job

[Imagine_]

Wow! Amazing...

[desertsniper]

dude first off... holy crap thats awesome! i love bethesda games and the new fallout series is great! you did a great job!

secondly! a job working for bethesda?! im super jealous as mentioned above they are my absolute game studio! I am an elder scrolls fanatic!

[TheFullMetalAlchemist]

Bitchin helmet, I want one!!

[owlart101]

Beautiful

[Josh Jay]

RE: Sonicase

Not sure how much it cost exactly. Quite a bit, but then again it was very trial and error from start to finish. All of the subsequent helmets I've made (I've made 4 total) have been a lot less expensive.

[Tomdf]

This is flippin excellent! Thanks for the info.

[sonicase]

nice job,

estimated total cost?

[ATTILAtheHUNgry]

Wow. a true fan. nice work.

[ilpug]

*Jaw on floor*

Okay, that is good. Wow.