Introduction: Fallout Ncr Helmet

Picture of Fallout Ncr Helmet

Hello this is my first instructable, and its my first helmet i have ever made. The ncr helmet with a few modifications. English is not my native language so bare with me.

First off download pepakura viewer

and the pepakura file by hugh

Materials you will need :

31x a4 Carton paper (thicker than normal paper)

2-4x Superglue

1x Scissors

1x Hot glue gun

4+ Hot glue sticks

Steel wire the size of your tube

1x Coka cola bottle cap

2-3mm thick foam pieces for inside padding

Small 7mm thick eva foam pieces for inside padding

Tube of your choosing i suggest something the size of the coke bottle cap

1x Tube locking thing

500g of fiberglass putty

500g of normal putty

1x Flashlight

1x Smaller flashlight

1x Antenna

Health and Security :

Use gloves,eye protection and a breathing mask when using putty.

Painting :

Black spray paint

Silver spray paint

Detail painting :

Acrylic colors blood red,burnt umber ivory black,phthalocyanne green and titanium white.

Silver marker for details

Step 1: Pepakura and Putting Things Together

Picture of Pepakura and Putting Things Together

Now open hugh´s pdo with pepakura viewer and print the pages, but before you print them all, test print 1 page if the lines or numbers are not on the paper then troubleshooting and instructions i suggest using this handy guide by Krsiak .

Now if you have printed all the pages. keep the pepakura viewer open it will help alot when trying to see where what part belongs. I started doing my piece from page 21, just cut the pieces and look for the numbers on the other pieces same numbers always go together. Use superglue to glue parts together. Continue doing this with all the pages. remember to check that the helm part is your size if it does not fit just take some part off or make paper carton pieces to fit inbetween the parts. When making the side piece with the flashlights you will have to modify the paper piece to make lights fit inside. If you want to have the flashlight thing removable put a magnet on the side of the helmet.

Tip : make some holes on the circular part in front of the mask it will help you breathe.

Step 2: Fiberglass in Normal Outside

Picture of Fiberglass in Normal Outside

Now its time to put some fiberglass inside the mask. Make little patches of the fiberglass putty, if you make too much it will begin to dry and will be of no use to you. Spread it all around the inside of the helmet and let it harden.

When it is hardened it is time to cover the outside with normal putty, same goes here make little patches of putty so it will not dry up before you can use it.

Tip: Remember to cover the flashlight lenses with tape so they will not get putty in them

Step 3: Sanding and Painting With Spray Paint

Picture of Sanding and Painting With Spray Paint

Time to sand the helmet, now if you want it to have less holes and scratches put another layer of putty on it and sand it again. After that its time to paint it. I spray painted it silver and then put black over it. Next i used green acrylic paint to make the helm have slight green color to it .

Now its time for some detail painting. I used the silver maker to make the lines pop more and make some scratches, then i used white,brown and black to make it look dirty and make some blood marks usin red.

Tip1 : If you want to make the dirt pop put white on the spot you want and make circles with your finger and take some of the white off with paper, then put brown and black on it and wipe it gently with paper.

Tip2 : remember to cover the flashlight lenses from paint

Tip3 : paint the cola cap black now before you put it on the helmet in the next step

Tip4 : if you want to make the helmet part look more green do not paint it black use something else.

Tip5 : if you want you can make scratches using sand paper

Step 4: Adding Detail Parts

Picture of Adding Detail Parts

Now its time to ad the antenna and the tube to the mask. take the tube and make a wire the length of the tube and bend it inside the tube add more wire if the tube will not bend.

Now add the cola cap on the other end of the tube with hot glue and tighten the tube lock thingy around it. Attach the other end of the tube where you want, i put mine in the hole on the side.

Time for the antenna, i glued it with superglue and then with hot glue. Time to paint it with dirty by using white, brown and black.

Inside the helmet i used the 2-3mm foam to make it comfy and the thicker pieces to make my head fit snuggly inside. I glued them using hot glue.

Making the eye lenses. I used some red sheet protectors cut it into pieces that fit the eye sockets.Now if you have skiing glasses now is the time to salvage those lenses and put them on the eyes. They work much better then sheet protectors.

Thats it i think,you have now made ncr helmet with some modifications congrats !!


PeterS562 (author)2017-08-26

What about using fiberglass resin as a base for the entire helmet before adding either fiberglass putty or regular Bondo putty?

This one guy on YouTube was making an Iron Man helmet and he first applied fiberglass resin before using Bondo fiberglass putty.

raymond.siebert (author)2016-10-07

Even think of casting that and making a mold? I was thinking of doing that with mine

JaniK1 (author)raymond.siebert2016-10-08

Nah i doubt i will ever make a mold. One helmet is enough for me and i do not have any space where to keep the molds, but i wish you the best for your molding project if you decide to do molding.

raymond.siebert (author)2016-09-25

Hey I had a question about the Fiberglass putty. Do you need to mix it with hardener or anything? Do you just take it straight out of the can and smear it on the helmet?

JaniK1 (author)raymond.siebert2016-09-26

The putty usually comes with a small hardener bottlethingy. You should take a small amount of putty and a very small amount of the hardener, about the size of a pea will suffice. Mix them together and put on the helmet.

raymond.siebert (author)JaniK12016-09-28

Forgot to mention, I'm curious on how many separate pieces you have there, is the helmet and mask separate? Is the light thing on the left side connected by a magnet or is it glued onto there?

JaniK1 (author)raymond.siebert2016-09-29

The whole thing is just one piece, the only thing that is removable is the lamp. The lamp is connected with a magnet so i can change the batteries easier. If you mean how many pepakura pieces there are i have not counted, probably alot.

raymond.siebert (author)JaniK12016-10-01

Hey so I was trying to find something for the eyes, but I can't find anything reflective and transparent enough, what did you use/recommend for me?

JaniK1 (author)raymond.siebert2016-10-02

I would suggest trying to look some discounts and marketplaces thats how i found my kids skiing glasses.

JaniK1 (author)raymond.siebert2016-10-02

first i had some rubbish red plastic but i could not see that well, so i found child skiing glasses that were cheap and used those

Alright thanks for the feedback, it helped alot. I was also wondering how you fiberglassed the microphone light thing on the left side of the helmet, did you do the inside first and then the outside? Or just the outside?

JaniK1 (author)raymond.siebert2016-09-30

No problem, always happy to help. I made the flashlight thing out of the pepakura and put first the fiberglass putty first to make it sturdy, then the outside with normal putty. If you meant the stuff on the helmet surrounding the flashlight, that area is just put there with superglue and covered in normal putty.

raymond.siebert made it! (author)JaniK12016-09-28

So I was looking around on the internet for other ways to harden it, and I ended up buying Fiberglass resin and the fiberglass mats, along with some body filler for the outside. Right now I'm still making the pepkakura, and I had some problems with the back part ( under where the helmet would be ) Because it was a little bit too small for my head. I noticed that you took some of those parts out of yours, but I didn't really see a clear shot of it. A pic of the back/inside would be very helpful. Here's a picture of where I'm at so far

JaniK1 made it! (author)raymond.siebert2016-09-29

Yeah that back thing was too small for me so i took the whole thing off. When i did the helm part i made a few extra pieces in the back of the helm to widen it to fit my head.

SergeiL9 (author)2016-10-01

Armored Skeptic? Nice. I was just watching Milo so it made me like you more.

ThijsD6 (author)2016-01-24

Do I miss something or isn't there any antenna .. xD?

JaniK1 (author)ThijsD62016-01-25

It´s there trust me. you just have to look at the pictures. The one i used was old wireless antenna.

Moral_Whale (author)2015-11-09

Is this an easy project or do I need to be experienced for it?

JaniK1 (author)Moral_Whale2016-01-25

this was my first i did. No need for much experience. Something you need is nerves when puttin it together

TheGuy155 (author)2015-09-13

Thank you for the help, this really helped me create my NCR outfite

JaniK1 (author)TheGuy1552015-09-14

no problem mate!

RAWRGuy (author)2015-08-20

Saw this posted on 9Gag after I saw it here. Did you post it?

JaniK1 (author)RAWRGuy2015-08-21

Yeah i posted it on 9gag. There i got the idea of making this tutorial

Konstantin Dimitrov (author)2015-08-20

I love the Fallout franchise and this helmet you made is awesome.

yeah me too, cant wait for fallout 4. thank you mate

I cant wait for Fallout 4 too, your welcome !

ethan_hair7 (author)2015-08-19

If you modify it a little bit it could be an Ant-Man helmet.

Yeah if he modified it, it could be an Ant-Man helmet.

skiedra (author)2015-08-19

steel be with you, brother. keep fighting the good flight!

dmwatkins (author)2015-08-19

Looks great! You wear it around the neighborhood at night, right? ;)

24Eng (author)2015-08-18

The weathered look you got was amazing! Thank you.

JaniK1 (author)24Eng2015-08-19

thank you kind sir !

ashleyjlong made it! (author)2015-08-18

Nice job. My boyfriend made a ranger costume in 2013 using a similar pepakura pattern but kept the helmet separate. He even installed a fan inside since wearing it can be pretty miserable!

JaniK1 (author)ashleyjlong2015-08-19

wow thats awesome and it looks great. Yeah it can get abit hot inside the helmet.

MsMaoMaoz (author)2015-08-18

Love it!

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