Angelus's Helmet Base Tutorial

13 Mar , 2012,
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It’s a brand new year, and we’re taking our cosplay tutorials in a new direction.

Rather than focusing on specific craft projects, we’re going back to basics with a series of simple guides that will arm you with the knowledge to create foam armor forms and patterns you can adapt to your cosplay needs.

And since we’re taking it from the top, we’ll start with a simple, circular helmet base design brought to you by our part-time warrior Angelus herself.

This tutorial will take approximately 45 minutes to complete.

Stuff you’ll need:

1. Some EVA foam

2. Contact Glue

3. Scissors

4. Wig stand

5. White glue or putty

You’ll also need a pair of compasses and either chalk or a soft pencil.

Step 1:

Measure the relative circumferance of your head around your temples. Next, use the pair of  compasses to draw a large circle on the EVA foam roll that’s approximately 2-inches wider than the circumferance of your head.

Draw out the base circle.

Step 2:

Next, cut out the foam circle using a pair of sharp scissors, and make several scour lines on the foam piece. Using more scour lines will create a more pronounced curve in your helmet, resulting in a rounder shape. Typically, six to eight lines should be sufficient.

Scour lines like so.

Step 3:

Cut up the circular foam piece along the scour lines. You’ll eventually end up with an oval shape and several crescent pieces.

You'll eventually get pieces like so.

Step 4:

Next, join the pieces together with contact glue, using the wig stand as base.

Make sure the entire surface is coated with contact glue...

... then join the pieces together surface to surface.

You'll eventually end up with something like this.

Step 5:

Cut a triangular wedge into the helmet base, then join the ends of the wedge together to create a round shape.

This groove wil give the helmet base it's shape when you join it together.

Step 6:

Using a piece of scrap foam, create the back piece of the helmet, join it to the base shape using contact glue, and you’re almost done!

Use another piece of spare foam to create the back piece of the helmet, and you're essentially done!

Finally, brush a thin layer of either white glue or putty over the join lines, and it’s ready for customizing!