Picture of 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

Picture of 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. 


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 :)

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.

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.

Mew14 made it!1 month ago
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.
BloodFeind8 months ago
Can you please email me at billyjbrixey@Gmail.com
georgespuiu8 months ago
paul.nasca.110 months ago

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....

The_Savior110 months ago

Make another one and sell it to me! I'll work up the money! How much to you want for it????

DAMN the Russians!

igor.jop1 year ago

how to scale prepakura model to my head dimension ?

fatlord1 year ago
So beautiful. So wonderful.

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.

KingKefir1 year ago

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

elisecv1 year ago

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

ajmalok1 year ago
Man! You work is FU#$&%* PERFECT !!! almost cry when I saw...AHIUAEHSIEHaishE

Perfect, really...
jackmaster1 year ago
Lucas T1 year 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!
novelchip1 year 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?
rchastain2 years ago
Do you think you can email me the helmet base if possible.
agm882 years ago
freakin awsome
awsomo-20002 years ago
can i just buy one from you?
Wow! Some day, I'm going to make this and never take it off.
fretted2 years ago


this is all i get it won't download like the file is gone !
poofrabbit2 years ago
Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!
TygrFr3d2 years ago
I absolutely love this mask! It's incredible how much detail you put into this.
oliver5202 years ago
Great Job, were you planning on ever seling one of these??
frankiboi892 years ago
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. =/
frankiboi892 years ago
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.


P.S.: Nice instructable :p
Josh Jay (author)  frankiboi892 years 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.
azreen3 years ago
Hi Josh,
It is Realllllllllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyy

great job done man.
aokona3 years ago
Pretty awesome all we need now is a field to play LARP with.
Jayjlow3 years 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)  Jayjlow3 years 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.
Sarel_Sarel3 years ago
You are a genius!
JoeMurphy3 years ago
great work. I don't make props, but this made me add it to my to do list!
polerix3 years 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!
I have never seen anything this impressive! The Force is obviously with you and you have many talents. Congratulations!
Josh Jay (author)  IconSpring6113 years ago
Fallout is probably my favorite universe in all of gaming so I really wanted to get this one right. Thanks again!
crispycat3 years ago
awesome tip! hope you win the contest!
Josh Jay (author)  crispycat3 years ago
Thank You! That technique has saved me hundreds of dollars in the last 3 years.
tech dawg3 years ago
one question.....how long did it take you to right this ible' ?
Josh Jay (author)  tech dawg3 years 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 dawg3 years ago
haha, thank you! I really wanted that Ms Pac Man table ;)
breumer3 years ago
Congratulations with winning the grand prize!!!!
Josh Jay (author) 3 years ago
Thank you for the votes and support!!!!!
Lorddrake3 years ago
amazing job
Imagine_3 years ago
Wow! Amazing...
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!
Bitchin helmet, I want one!!
owlart1013 years ago
Josh Jay (author) 3 years ago
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.
Tomdf3 years ago
This is flippin excellent! Thanks for the info.
sonicase3 years ago
nice job,

estimated total cost?
Wow. a true fan. nice work.
ilpug3 years ago
*Jaw on floor*

Okay, that is good. Wow.
Josh Jay (author) 3 years ago
RE: mikessaurus & Xolin- Yes, the rest of the armor is in the planning stages right now. However, I need to finish the Gauss Rifle I started:


I thought a suit of armor without a weapon to hold would be a bit awkward so I took a break from the armor. I just took a job at Bethesda (start next week) and need to find a place and get settled in before I can resume work.

RE: jessyratfink- Thank You! I'm happy to be a part of Instructable family and seeing all the great stuff people are sharing here.

mikeasaurus3 years ago
AMAZING build! Do you have plans for the rest of the power armour?
You are awesome! This is the best. Seriously one of the most beautiful builds I have ever seen. I wish I had the talent to reproduce things like this! I would have Fallout everything.
Xolin3 years ago
That is just simply awesome! Well done. Excellent, detailed instructable... I take it the rest of the outfit will follow in coming 'ibles..? :-)