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
  • 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. 

<p>Error 404- Comment not found for sheer happiness of what I just saw</p>
<p>my son is a massive fan of fallout games would love to buy one if your selling</p>
*cries with happiness and creates a river of eternal joy* sorry. :P. I &lt;3 fallout. Favourited. I'm only 14 but one day I have to build this :)
<p>???no comment blown away</p>
<p>I was wondering what specific product you used for the gel, how much was needed and how much it cost. I really like this concept as an alternative to fiberglass and bondo and I am planning to try it out myself.</p>
<p>Awesome work!! Thanks for chairing!</p><p>I want to start the project, but the fact that the files from the links you chaired come with viruses is annoying me...</p><p>I don't want to open the files given this, so I'm kind of stuck...</p><p>Is there any other place where I can get those files?</p><p>Thank you</p>
<p>This is Awesome!</p>
<p>Unless I am doing something wrong it appears that the PEP file is no longer available on 4Shared.</p>
<p>Nevermind. I located it. Once you hit the small Download button (Small white/gray button) You have to hit the &quot;Free Download button on the next page to start the countdown. After the countdown the file will download.</p>
<p>Awesome, it makes me wonder how much a real stainless steel casting would set me back. You made such quality moldings ... at least it looks to me that way.</p>
You are flipping amazing!
<p>I'm building my own helmet at the moment - the mould lol i dont have the money neither access to some of the products. I cant for the life of me find the big rubber tubes you used on yours. Could you please tell me what tubes you used and maybe where you got it from? thanks :)</p>
<p>it almost gives you the idea of the gaiters on a motorcycle however thats very expensive and far too short. I'm close to surrendering and using pool piping but it struggles to get the bend and look i need. some rubber ducting pipes are similar to yours and gets a better bend than pool pipes maybe i can find some off-cuts somewhere.</p>
<p>I know this post is 10 months old but I had the same issue. What you want to find are WW2 Czech gas masks, also labeled under ww2 russian gas masks. They also sell the hoses themselves on Ebay from time to time but the cost is similar to just buying the whole WW2 mask, expect to pay around $10-20 a hose.</p>
Hey thanks for sharing the pep model you created. This is the first of several fallout props of plan to make. Next on my list I'd planning the tesla armor patterns. I'm a bit of a larger guy so modifying the model into wearable patterns is going to be a challenge.
Can you please email me at billyjbrixey@Gmail.com
<p>Thank you so much for taking the time and effort to post your work! You saved me a ton of grief on my build! Here is to Fallout 4....</p>
<p>Make another one and sell it to me! I'll work up the money! How much to you want for it????</p>
<p>DAMN the Russians!</p>
<p>how to scale prepakura model to my head dimension ?</p>
So beautiful. So wonderful.
<p>Really enjoyed your post. Would like to learn more about how to use the file you provided and the software. I found both of them but am struggling how to make them work. </p>
<p>This is awesome, thanks for sharing your excellent work with us.</p>
<p>It's absolutely amazing, I wish I had your skills!</p>
Man! You work is FU#$&amp;%* PERFECT !!! almost cry when I saw...AHIUAEHSIEHaishE <br> <br>Perfect, really...
Hay Man, Amazing Work, Fallout 3 is my all time favorite game and i feel &quot;required&quot; 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! <br>Thanks for your time and work!
awesome work. <br>
no no good work thank you
your link doesn't work
In this way, the body and the legs do I create? <br> <br>We want to hear from you
Did you measure the circumference of the head in any way?
Do you think you can email me the helmet base if possible.
dude <br>freakin awsome
can i just buy one from you?
Wow! Some day, I'm going to make this and never take it off.
<br>bos_helmet.pdo <br> <br>this is all i get it won't download like the file is gone !
Congratulations on being a finalist in the Halloween contest!!! Can&rsquo;t wait to see if you win! Good luck!
I absolutely love this mask! It's incredible how much detail you put into this.
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. <br> <br>Thanks, <br> <br>P.S.: Nice instructable :p
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.
Hi Josh, <br>It is Realllllllllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyy <br>ROCKINGGGGGGGGGGGGGGG G G G G GG G G <br> <br>great job done man. <br>
Pretty awesome all we need now is a field to play LARP with.
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 &quot;dot&quot; out of the URL but 4share.com is saying that the link is invalid or that &quot;The file has been deleted because it was violating our Terms of user <br>Read more at.&quot; Can you upload the file to another source? like dropbox or something of that nature? THANKS!
Would it be better if I just email it to you later tonight when I get home from work? <br>You can send me a message at Instructables with your address.

About This Instructable




Bio: I am a video game environment designer by day. I am a prop builder by night.
More by Josh Jay:The "Highwayman Inn" (from Sketchup and 3DS to Reality)The Engagement Box (from 3DS and ZBrush to Reality)Fallout 3- Brotherhood of Steel Helmet
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