Introduction: Metal Helmet (Leyla Agosti)

The metal helmet was used during Antiquity. Indeed, this piece of armor allowed the warriors to protect their heads during the fighting. These helmets are no longer useful, given their inefficiency in the handling of firearms. They remain nevertheless of great interest and the work behind their design remains all the more interesting.

That's why I decided to build my own metal helmet inspired by the Middle Age helmet. In addition, this project allowed me to work with my father who taught me a lot, such as welding and metalworking. This project was a challenge for my dad and me because none of us really knew where to start. Moreover, it was a different work from what the school usually asks us to do, and I must admit that I am quite proud of the result.

This mask has a layer of foam on the inside to ensure that it is safe and comfortable, also deer horns are attached to the top of the helmet. Its main purpose was simply decorative but, this helmet can be worn as a disguise. In addition, if combined with armor and a sword, it could be used for role plays.

Step 1: Material and Tools

- Steel plates (2.69mm/ 12 gage) (0.93mm/ 20 gage)(0.89mm/ 21 gage)

- Contact glue

- Protective foam

- Varnish (for finishing)

- Deer horns (decoration)

- A gear (decoration)


- Welder

- Steel angle grinder

- Orbital sanding machine

- Sand paper

Step 2: The Base of the Mask

I cut the steel and then I folded it to get the pieces needed for the construction of the mask

Then I welded the piece together to get the base of the mask

Step 3: Welding of the Main Part of the Helmet

I added thicker steel strips to hide the weld points and I welded the eyebrows and the nose to the helmet. I also added a larger steel strip to allow the mask to be worn

Step 4: Welding of the Perforated Steel

I placed perforated steel strips on the cheeks and eyebrows to hide the weld spots and add texture to the helmet.

Step 5: Deer Horns and Other Decorations

I made two little holes in the upper section of the helmet so I could fix the deer horns. Then I welded a gear in the middle of the forehead to hide the welding spots and to make it look nicer.

Step 6: Sanding, Sandblasting and Varnishing

I used a sander and sandpaper to reduce the appearance of weld spots and give a more even finish to my helmet.

I also polished the mask to have a brighter steel

Step 7: Protective Foam Installation

I cutted the remaining foam that I found in my garage and I installed inside the mask to promote the comfort and safety of the user.

I also used contact glue that I applied on both surfaces to be sure to have the best aderance between foam and steel. Let the glue dry for an hour.

Step 8: Conclusion

After installing the protective foam, the helmet is complete and can be worn.
This project was very interesting and I plan to make a sword that can fit with the helmet.

The main problem I had to face was the limited time I had to do this, because during the school year I live in residence and my house is very far from my school. In fact, I come home only on weekends so I had access to my garage only 2 days out of 7.

Plus, it was the first time I had used a welding machine by myself because normally my dad used to do it for me. In fact I got a little burned sometimes and I cut myself often. But with practice, I have improved

I think this helmet is pretty cool but I have to admit that next time I will put the mouth a little higher and I would have used elastic instead of a steel band for the back of the helmet.