Instructables

Making a Japanese Kabuto (兜, 冑) Helmet using Worbla Thermoplastic.

Picture of Making a Japanese Kabuto (兜, 冑) Helmet using Worbla Thermoplastic.
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Kabuto (兜, 冑) or Japanese War helmet worn by samurai

Elements of the helmet that I will try to incorporate into my model.

Hachi (helmet bowl)

Shikoro (neck guard)

Tatemono or datemono (helmet crests)

Fukigaeshi (wing- or ear-like projections on both sides of the kabuto)

Mabizashi (brim or visor)

Shinobi-no-o: Kabuto would be secured to the head by a chin cord (shinobi-no-o)

Ukebari (hachi lining

Link to more information.
 
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Step 1: Tools that you will need!

Picture of Tools that you will need!
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Step 2: Worbla Thermoplastic

Picture of Worbla Thermoplastic
"Technical specs:
Use hot air, water or steam (min 200°F) to bring this plastic to the shape you want to (heatgun recommended). The material can be heat-formed even after repeated cooling, it is safe to use and solvent-free. Unlike other heat-formable plastics, Worbla leftovers can be molded and shaped like clay, so there is almost no waste. Worbla hardens very fast and can be sanded. The extra glue coating on the shiny side makes it very easy to attach several layers by heating up the pieces, as well as attaching additional components. Start with a thin sheet then build up, or create sturdy pieces with multiple layers from the start."

Link to where I got my thermoplastic.

Step 3: How to get the correct shapes.

Picture of How to get the correct shapes.
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I cut out the shapes I needed first in construction paper. Construction paper is cheap and if the shape is wrong I just draw it again! I then use the construction paper template to draw the object in to the Thermoplastic.

Step 4: How to cut Thermoplastic

Picture of How to cut Thermoplastic
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It is easy to cut you can use a sharp knife or scissors. 

Step 5: How to reshape Thermoplastic.

Picture of How to reshape Thermoplastic.
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Heat the plastic to 200 degrees Fahrenheit. I used a heat gun to do this.

Link to a shaping tutorial.


Step 6: How to Video links.

Picture of How to Video links.

Step 7: It is easy to connect two pieces together.

Picture of It is easy to connect two pieces together.
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The shiny side of the plastic has a glue / adhesive coating so after heating you can attach pieces together to build up your object. 

Step 8: Other ways to form the plastic to a shape.

Picture of Other ways to form the plastic to a shape.
You can do it by forming the plastic by hand or by using a mold or object that fits the shape you want

Step 9: After you get the plastic in the correct shape let it cool.

Picture of After you get the plastic in the correct shape let it cool.
These will allow the plastic to harden to the shape you want it in.

Step 10: The helmet is now done!

Picture of The helmet is now done!
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Step 11: Next step is to paint!

Picture of Next step is to paint!

Step 12: I used Clear Gesso for the first layer.

Picture of I used Clear Gesso for the first layer.
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Nice work. You should put a picture of your final creation as the first picture to give people an idea of what you made
moverstreet007 (author)  mikeasaurus1 year ago
Yes, very good idea! It is done.