loading
So for you fans or The Elder Scrolls franchise, or just simply Skyrim. Here's one of the most iconic helmets in the game. This is my first time crafting so it's a great great risk for me to do it. But hell, it's been fun and I finished it nicely. :) ENJOY!

Step 1: Materials and PEPAKURA!!!!!!

Materials!!!! 
Thick paper/board (a4)(make sure it fits in your printer, haha)
PVA Glue
Scissors/Cutter
Fibreglass mat
Clear cast resin (two part)
All-purpose Epoxy
Plaster of Paris (or if you have more budget, body filler)
Sculpting tools (I actually only used cutters, small files because I didn't have pro sculpting tools with me)
Sandpaper 
Matte spray finish 
Primer
Black paint
Silver paint
Brown and yellow water based paints (or just go get your poster color set, or watercolors.)
brush
old worn out brush
acetone
paint thinner (depends on what paint you're using)
plastic cups
protective gloves


PEPAKURA!
I'm well aware that not everybody is familiar with Pepakura and 3d modelling, so I'm making it easier for you. 
Pepakura is a program that unfolds 3d models so you'll be able to make a real life papercraft model of it.

So I downloaded a model from sketchup community component models and reduced the planes for papercrafting, after then I unfolded it in Pepakura and printed it out on a thick paper. If you've never done this before, every edge of the pieces are numbered, where there's another piece that has the same number on an edge, that means they go together. there's a positive piece and a negative piece, if you can see there are flaps to some edges and to some there isn't. when you find the same numbered ones, you'll have to stick the one with a flap to the back side of the one without a flap so their edges would meet. always keep it front side up, if you get me. if you keep on reversing sides you'll just mess the model up sooner or later.


*Oh! What's that right there? A file! must be the papercraft file! Try it now will you?*
the paper is set to a4. the diameter of the helmet is about 25cm I think

Step 2: Fibreglassing!

So after you finish the papercraft model. Prepare your clear cast resin and fibreglass mat. WEAR YOUR PROTECTIVE GLOVES! (I like wearing 2 to 3 layers of gloves when working with resin, I'm just too paranoid. haha)

The resin has two parts, the ratio depends on the brand you're using, so make sure you read the instructions on the container first! 
Mix them in disposable plastic cups, or any plastic cup you won't use  for consumption anymore ever. Don't use styro cups because the resin will dissolve it.
Now prepare a cup with acetone(CAREFUL!), to clean up your brush after using it with resin.

Mix a few ounces of resin on your plastic cup and brush a few layers on the exterior of your helmet and horns. now wait for it to dry. make sure there's no part left without resin.

(NOTE: it's better to use Aluminum foil rather than paper to dry it on, because it doesn't stick permanently to resin)

Now when the whole thing is dry, turn the helmet upside down. Cut a few pieces of fibreglass mat, maybe 2x2inches. Brush some glue, or if you have spray glue, then spray it on the inside of the helmet then cover it with fibreglass mat. Again, make sure you don't leave any part without mat. 

Now mix a few more ounces of resin on your plastic cup and brush it over the insides. Now while curing, it's gonna be hot, because of the reaction of resin and fibreglass. Do not touch it. leave it for a few hours before you go to the next step. :) 

*NOTE: since I can't put the fibreglass inside the horns, I just coated it with fibreglass and resin outside. It works just as fine. :)


Step 3: Sticky Sticky

So after fibreglassing, when everything is set and cured properly, prepare your all purpose epoxy. I'm using two part pink epoxy. 
Now put a little on the horns and a little on the helmet, just right where you're gonna connect the two. Dry it up a bit then stick the horns to the helmet. you can put tape around it for support so it won't get misaligned. it usually dries in 3 hours and cures fully within 8-10 hours. 

now this next one is optional but i like doing it so the Plaster would have something to hold on to. Prepare some of your epoxy again and put some all over the whole helmet and dry it up for an hour. . . then on to the next step :)

Step 4: PLASTER AND SCULPT!

Now this would be different if you're using body filler, but since I used plaster, I'll be explaining how i did it with plaster. :) 

Now get your plastic cups again and mix water, PVA glue, and plaster. the ratio should be 1:1:2 in the same order. Then while your epoxy is a little soft, brush in the plaster mix on the whole thing. it's gonna be a little frustrating trying to make it really thick. It took me numerous layers before the thickness I wanted. don't let the plaster cure fully before you brush the next layer, because it will just crack while you're sculpting it. 

Now when it's fully cured, sculpt some crack and details, it would be easier if you brush or spray water on the surface you're gonna sculpt, the plaster will be a little softer then. 

Then you can use the sandpaper on the parts you think are really rough. but leave rough parts because it could add to the aged effect.

Step 5: PAINT! Part 1!!!

Now this one is easy. Brush in primer on your helmet. 

Then mix a few browns and yellows with water and just wash it over the horns. this way the paint will seep through the dents and would look like dirt on your horn. repeat this step until you're all good with how it looks. 

Now for the "IRON" part. Paint it all black(no, not including the horns). then when it's dry, go pick up your worn out brush and brush in very light layers of silver paint. don't be too careful, just brush it randomly. Now this would give you a good "old steel" look. Don't worry about making it clean, it's supposed to look old and dirty. 

now my faaaaavorite step! NEXT! 

Step 6: FINISHING!

Now get your brown paint again and mix it with your yellow one again, then get your other worn out brush. or you can use the same one you used just a while ago, it's okay, make sure you clean it tho. 

Then you can either use cotton balls, or if you're feeling sloppy, use your hands. brush a few of your paint mix around the helmet. yes, randomly. and dab the cotton on the painted parts, or your hands. 

then we're there! VOILA! you now have a helmet... 

woops! spray some matte finish on it first. I forgot that one. eeeek! 

if you don't have any, just get your resin, I'd bet you have more than some left. and brush a thin layer over the paint. so it won't fade. 


okay now we're really done. GOODLUCK!

HOPE THIS HELPED! 
<p>Vuus Nah!</p>
<p>FUS RO DAH!!!!</p>
EVERYTHING YES!!!!!!!!!!!!!!!
<p>This is simply amazing. I downloaded and printed the template from here. I hope to make it for my dovahkiin costume next year</p>
Not ad good, but I'm happy with it! :) thanks for the help!
<p>It's really awesome! No problem love! </p>
Hey I'm new to this as well and I am at the plaster and sculpt phase but was wondering how to sculpt it. I'm using Plaster of Paris and the consistency is more liquidy than i anticipated, i was expecting more like a clay. So i guess my question is how to work with the plaster. Thanks!
<p>what I did was I brushed the whole helmet with layers and layers of plaster until it was thick enough to sculpt (about 7mm). If you want something more like clay, you can maybe use paper clay, or apoxie sculpt :) </p>
Awesome! Thanks! What tool do you find is best for sculpting the plaster? And do you let it harden first or sculpt while its still wet? Thanks again!
<p>I just spray water when it's dried. :) tho don't let it fully dry, that would be about 2 weeks without any moisture. it would be harder then. im just using random carving tools. mostly knives, cutters, xacto. then I use dremel to clean up and detail. </p>
<p>Me again :( I have the body filler but seeing as you used plaster and have instructions for that I am thinking perhaps I should switch products? Any thoughts? THanks again!</p>
<p>well, this depends on how you want things, I used plaster because I only had a few days to finish up, and it's easier to smooth and sculpt, just spray a bit of water and it's like carving a watermelon. only negative side is, it cracks easily, well of course with outside force. Mine is still as good as new to this day. Bondo is tougher, you can basically use it as an actual helmet and it could take more force before it cracks. But it's harder to smooth and sculpt. </p><p>My advice is, if you're just using it as costume , use plaster, it's easier to manipulate and make beautiful. Seal it in with a layer of resin after carving and before painting. But if you mean to use it as an actual helmet then bondo is the way to go. Tho mind you, with the epoxy and fibreglass treatment, no matter which you choose, the helmet could still protect your head. hahaha Anyway, best of luck! </p>
<p>Sorry for the delay :P Finals week! The only thing that worries me is making that crack in the Bondo as I can't just wet it to sculpt it in? But I'll try my best. : )</p>
<p>Okay, sorry, I am very new to this! Bondo is available on Amazon for about 8$ a pint and Elmer's (like the glue company) has 9 square feet of fiberglass mat for about 7$ and I was wondering if these sounded good to you? And if that sounded like enough material! :S</p><p>Also, would this helmet fit an adult male? If not I can adjust it by hand after I print. I'll measure just to make sure, though!</p>
<p>I think that would be more than enough. Also, yes it would fit an adult male, as I have a rather large head for a woman hahaha. </p>
<p>Thank you so much for replying! :3 Just printed it out and ready to give it a go! I saw someone posted a video link on people making it. I might watch that, too. Lol. Thank you again! You've made my (and my boyfriends) year by posting this!! :&gt;</p>
<p>no problemo love :) </p>
<p>Oh and what kind of primmer? I have Gesso from a previous project, does this work??</p>
<p>yeah, gesso would do nicely</p>
<p>ok i have a very nooby question! the pdf file, im assuming that the dimensions in there are in &quot;ready to print&quot; conditions right? means to start making it ,all i gotta do is print that pdf on A4 sheets right?</p>
<p>Yep. Go for it.</p>
and the file? :(<br>(nice work :D)
<p>https://www.instructables.com/files/orig/F42/41VR/H2MYLR1K/F4241VRH2MYLR1K.pdf</p>
<p>what did you do for the inside of the helm?</p>
<p>Wow, I wonder if i could do this some how</p>
If i wanted to cut some time and the cost, could i drop the plaster? I'm making this for a friend's birthday.
did you use prang?
for the horns, yes. but keep in mind to set it with a coat of spray finish so it won't come off. :)
Did you print on larger paper or did you just use the a4 format? <br>
I just used a4 :)
You' are a idol! I love it!!!
thank you dear! ;)
Done with the paper helm! : D <br>But i don't know how to add resins nor plaster <br>
Is arranging the actual pepakura helm hard <br> <br>I've never really created anything yet.....It's my first time
it's not really that hard, you can find videos on youtube on how to do it. Tho you need a little patience. and a lot of paper. you can use any paper as long as it's thick as much as possible.
Cany really find good paper to use :(
What kind of paper should i use for the paper model
Any kind of thick paper would be nice. :) you can also recycle used paper. in my case I used all my thesis drafts for printing and glued it in old carton boxes. to make it thicker :)
Congratulations on being a finalist in the Halloween contest!!! Can&rsquo;t wait to see if you win! Good luck!
wow! I was? I didn't even know. haha thanks for telling me, and thanks for cheering me up! *hugs
thats a sick lookin sculpt n1
Nice work! I haven't read through the actual instructible yet, but the finished project is awesome! FUS RO DAH! :^D
Okay, so I had a body filler. Paperkraft, added body filler. Got confused didnt add glue to plaster, plastered helmet. What to do now, remove plaster and sand down body filler? Then paint? Right?
My fault, I forgot to mention that if you're using body filler instead of epoxy you wouldn't have to add plaster. so it would be better with only the body filler if you can properly sand it down to a clean finish :) I just chose epoxy and plaster and glue because in my country body filler is so pricey. :)
Well, I wasn't copying your tutorial correctly, so I bondo'd the helmet I put plain old plaster on it now I don't know how to remove the plaster..... Help?
i guess you can either sand down the plaster itself or use water to wet the plaster and sculpt it off. goodluck! If it were me tho, I'd just sand down the plaster instead of taking it off. just finish it with resin so it would hold into place, since it would be a little fragile without the glue.
Hi there, just wanted to post my finished helm using your method. <br> <br>Thanks for the great Instructable! <br> <br>gallery of the build stages: http://dindendi.deviantart.com/gallery/ <br>
NICE WORK MATE! :D glad you liked my instructable :)
Do you still have the original PDO file? I'm having a bit trouble understanding connection point 45 and 51. A 3d picture would help tremendously. Great instructable, though! <br>
im at the office now so i don't have access to my laptop. I'll try to search for it once i get back home and send it to you. message me your email :)

About This Instructable

101,157views

521favorites

License:

More by chichill:Captain America Stealth Helmet Jeff the Killer Mask How to: Easy Halloween Prosthetics 
Add instructable to: