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Fallout 3- Brotherhood of Steel Helmet

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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.


 
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Step 1: Chapter 1- Planning- 1: Measurements


Tools and Materials
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

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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. 


Really enjoyed your post. Would like to learn more about how to use the file you provided and the software. I found both of them but am struggling how to make them work.

KingKefir2 months ago

This is awesome, thanks for sharing your excellent work with us.

elisecv2 months ago

It's absolutely amazing, I wish I had your skills!

ajmalok3 months ago
Man! You work is FU#$&%* PERFECT !!! almost cry when I saw...AHIUAEHSIEHaishE

Perfect, really...
jackmaster4 months ago
THIS IS AWESOME!!!!
Lucas T4 months ago
Hay Man, Amazing Work, Fallout 3 is my all time favorite game and i feel "required" to try my hand at crafting one of these things! I have gone through the tutorial and and added everything i think i will need for the project into my amazon cart and i guess my big concern is the amount! you never really specify on a what a good amount of a given material should be purchased. Is there any way you could add a list in the beginning of your guide with an approximate estimation on each material for one complete helmet!
Thanks for your time and work!
novelchip6 months ago
awesome work.
no no good work thank you
your link doesn't work
In this way, the body and the legs do I create?

We want to hear from you
Did you measure the circumference of the head in any way?
rchastain8 months ago
Do you think you can email me the helmet base if possible.
Xlanar11 months ago
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.
agm8811 months ago
dude
freakin awsome
can i just buy one from you?
Wow! Some day, I'm going to make this and never take it off.
fretted1 year ago

bos_helmet.pdo

this is all i get it won't download like the file is gone !
poofrabbit1 year ago
Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!
TygrFr3d1 year ago
I absolutely love this mask! It's incredible how much detail you put into this.
oliver5201 year ago
Great Job, were you planning on ever seling one of these??
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. =/
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 (author)  frankiboi891 year ago
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.
azreen1 year ago
Hi Josh,
It is Realllllllllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyy
ROCKINGGGGGGGGGGGGGGG G G G G GG G G

great job done man.
aokona1 year ago
Pretty awesome all we need now is a field to play LARP with.
Jayjlow1 year ago
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 (author)  Jayjlow1 year ago
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.
You are a genius!
JoeMurphy1 year ago
great work. I don't make props, but this made me add it to my to do list!
polerix1 year ago
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!
Josh,
I have never seen anything this impressive! The Force is obviously with you and you have many talents. Congratulations!
Josh Jay (author)  IconSpring6111 year ago
Fallout is probably my favorite universe in all of gaming so I really wanted to get this one right. Thanks again!
crispycat1 year ago
awesome tip! hope you win the contest!
+1vote
Josh Jay (author)  crispycat1 year ago
Thank You! That technique has saved me hundreds of dollars in the last 3 years.
tech dawg1 year ago
one question.....how long did it take you to right this ible' ?
Josh Jay (author)  tech dawg1 year ago
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.
wow thats a lot of work i congratulate you for being able to do something like this fantastic job!
Josh Jay (author)  tech dawg1 year ago
haha, thank you! I really wanted that Ms Pac Man table ;)
Outstanding!
breumer1 year ago
Congratulations!
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