How to make a cosplay helmet!

Always wanted to make a helmet from Halo, Daft Punk, Gears of Wars, or any other iconic character that you like a lot? This instructable is for you! (And it works for armor too!)

Obs: This is my first instructable, and if there is any grammar mistake, sorry, english isn't my first language! and the .PDO for Guy's Helmet is in step 2.
Obs²: Gloves tutorial are now on page 10!

Remove these ads by Signing Up

Step 1: Materials

FIRST: If you don't have patience, just leave, you need A LOT OF PATIENCE!
*Pepakura Viewer 3
*.PDO file of your desired helmet (.PDO for Guy's Helmet is in step 2)
*Printer
*Paper (Of any kind, but I use cardstock)
*Glue
*Scissor or X-acto knife
*Fiberglass and Fiberglass resin
*Bondo (Car Body Filler)
*Sandpaper
*Paint
*Primer

degomag says: Dec 18, 2012. 4:28 PM

Boa japa!

FabiojapaXD (author) in reply to degomagDec 18, 2012. 5:15 PM

Valeu!

o__o says: Aug 25, 2012. 7:07 PM

What did you use to stick the peices onto the gloves? Nice work btw. :)

FabiojapaXD (author) in reply to o__oAug 26, 2012. 11:29 AM

Thank you! I used simply hot glue gun! It works wonders actually!

o__o in reply to FabiojapaXDSep 16, 2012. 6:44 PM

Cool thanks! I'm making a daft punk costume. This helped alot. :D

FabiojapaXD (author) in reply to o__oSep 16, 2012. 6:54 PM

And that is very nice to hear! You may ask anything you want, someone to help is very useful! (

ikendall says: Aug 9, 2012. 12:32 PM

vai Brasileiros/as no Instructables!!!!!!!!

FabiojapaXD (author) in reply to ikendallAug 9, 2012. 6:10 PM

Woooooo! Brasileiros dominando a internet! \o/

thealerosenbaum in reply to FabiojapaXDSep 13, 2012. 10:42 AM

lol, parabens cara, jÃ¡ tinha ficado fod@o, mas agora....xD!

FabiojapaXD (author) in reply to thealerosenbaumSep 14, 2012. 10:12 AM

lol valeu xD

Shonswer says: Aug 27, 2012. 3:01 PM

It's like Daft Punk style! Nice tutorial bro!

FabiojapaXD (author) in reply to ShonswerAug 27, 2012. 4:45 PM

Thank you very much!

PeckLauros says: Aug 18, 2012. 2:50 PM

Da para colocar o esquemático ou pelomenos um esboço do circuito eletrônico?

FabiojapaXD (author) in reply to PeckLaurosAug 20, 2012. 12:21 PM

Pronto! Coloquei o circuito na pagina 8!

PeckLauros in reply to FabiojapaXDAug 21, 2012. 12:28 AM

Valeu! Ficou Fda!

ThunderDrums says: Jul 31, 2012. 10:32 PM

When you put the fiber glass mat/cloth on how did you keep the paper structure from collapsing on itself?

FabiojapaXD (author) in reply to ThunderDrumsAug 1, 2012. 1:54 PM

Here's a tip: First, I glued the fiberglass cloth in the helmet, with normal, white glue, and then I brushed the resin over it, so it wouldn't collapse or distort so much! But, try to fiberglass THE INSIDE, and put some wooden pieces on the sides, so it won't distort! (If some distortion occurs, take a heat gun and gently heat the warped part and try to bend it in place)

DoctorWoo says: Jul 21, 2012. 7:18 PM

Don;t suppose you have the file for Guy's DaftPunk helmet, do you...?

FabiojapaXD (author) in reply to DoctorWooJul 22, 2012. 8:48 AM

No, I lost my file and the link I used to download was on Megaupload. Sorry man. If I find one similar I'll post the link!

DoctorWoo in reply to FabiojapaXDJul 22, 2012. 1:13 PM

Drat. Been looking for those for some time. But this is a great find none the less! Really helpful for any sort of prop making!

However, I got one more question...you said you vacuumed formed the visor..do you have a vacuum form machine, or do you have some sort of a nifty trick of the trade?

FabiojapaXD (author) in reply to DoctorWooJul 22, 2012. 1:31 PM

I did try to make a Vaccumformer, but it didn't worked as suposed to. (It was simply a box with a hole for a vaccum cleaner hose and a lot of small holes on the top)

One visor I made with the vaccumformer looked great, but it was too smal do install on the helmet, so I made one by simply heating the PETG plastic in the oven and putting it over the mold, simple like that!

PS: I've uploaded a file that I found, it's not mine, I'm only uploading it!
http://www.4shared.com/dir/wvwjyYAJ/_online.html

DoctorWoo in reply to FabiojapaXDJul 22, 2012. 2:12 PM

Oh! Thats clever! I used one a few times when doing some 3D modeling in school. Very nice machines to have, and from the looks of it, easy concept to clone!

I'm actually planning to make a helmet here soon, and the visors *always* threw me off. I've seen and heard of some people actually getting a thin plexglass and using a heatgun to form the visor...have you ever tried that...?

FabiojapaXD (author) in reply to DoctorWooJul 22, 2012. 3:28 PM

Yes, because the visor that IS mounted on the helmet was made somehow like you said, but instead of a heat gun, I used a oven xD But eventually, I'll buy a heat gun, very useful for me!
And sadly yes, the visor is the worst part of the build, but when you start to get it right, you will feel awesome! So, if you do make a helmet, send me a picture!
And I didn't used plexiglass, but PETG, a plastic that was 0.75mm thick!

DoctorWoo in reply to FabiojapaXDJul 22, 2012. 3:57 PM

Ah! PETG, that's what I was thinking of! I've vaguely remember another plastic people have used for visors, but my memory failed me XD
But I will certainly upload some pics when the project gets underway! Hopefully I can find a good model here soon!

FabiojapaXD (author) in reply to DoctorWooJul 22, 2012. 4:02 PM

For the guy manuel helmet? Didn't you see? I said I uploaded it!
http://www.4shared.com/file/GjlA4-nw/Guy_Manuel_Helmet.html?

DoctorWoo in reply to FabiojapaXDJul 22, 2012. 4:20 PM

:O I didn't! Oh, man...your my new best friend! Thank you TONS for that!

FabiojapaXD (author) in reply to DoctorWooJul 22, 2012. 4:32 PM

Your welcome man! I found the file hidden in some part in my computer and thought that would be useful for a lot of people! And don't forget, I want to see the pictures! xD

DoctorWoo in reply to FabiojapaXDJul 23, 2012. 2:30 PM

I defintaly will!!
But, before I do..I got one finally question: how'd you tint the visor? Did you buy the PETG pre-tinted, and if so, from where?

FabiojapaXD (author) in reply to DoctorWooJul 23, 2012. 3:16 PM

My visor, I bought the normal PETG, and used a paint, but I can't tell you the name because I'm from Brazil, so you wouldn't be able to find, but it was a paint used to tint tailights of cars, the American one I think is VHT Nite Shades, it should work just like mine!
PS: The image below shows the visibility of the visor :D
Good luck with your build, any question just ask me!

DoctorWoo in reply to FabiojapaXDJul 23, 2012. 4:29 PM

Oh! Alright, perfect! Thanks for that!
And I think I lied...I need one last bit of info for this...don't supposed you have the wiring schematic for the lights, do you...?

FabiojapaXD (author) in reply to DoctorWooJul 23, 2012. 5:10 PM

Actually, I do xD The Controller was this one: http://www.eleccircuit.com/wp-content/uploads/2007/05/led-chaser-by-ic-4017-ic-555.jpg (Connected to 8 AA batteries, resulting in 12v) and the led boards, I simply used 4 5mm ultra bright leds in parallel, with one 470 ohms resistor for each one!
The design for the controller board, sadly, I can't upload for you because it isn't mine, but for the leds I'm attaching a print screen for helping you!