The Helmet easily takes the longest to fabricate; especially when it's a first attempt.
As a prototype, this finished helmet consists of approximately eighty individual parts; many of them could be consolidated together.
Again, the first step is to transpose the wearers measurement into a framework upon which to attach the basic shell of the helmet. Getting the helmet dimensions is a challenge. I started by taking key measurements of my sons head: circumference from above the eyebrows, distance from eye to bottom of chin, distance from eye to top of head etc. I used number 2 wire to capture his head shape. From these I created a frame upon which to temporarily position the key parts and create the dome.
TIP - Once you have the circumference, cut the wire to that length, then bend the wire around head to capture basic shape, lay the wire flat on cardboard and mark around shape adding a further 5-10mm all around so helmet doesn't end up too tight.
Many of the parts were created by simply snipping away at a piece of cardboard until I'd found the right size and shape.
For the dome I used a combination of Honus's
method and papermache; using a blender to pulp the papermache to a very smooth consistency. The dome consists of a base layer of cardboard, upon which paper mache was used to get a more accurate shape and a thin layer of Super Filler to smooth off.
A blue LED light was installed at the end; this shone from the back of the 'Mohawk'.