The most popular posting on my blog by far is for my Loki helmet I made a few years ago, and it's been one of the crown jewels in my collection. You can see my original build by clicking here.
Without going into too much detail, I no longer have it and I've been itching to start making one again. But for this one I am going to do things differently. Below is a picture of a bike helmet. I see these helmets constantly and they are made almost entirely of foam.
So I decided to order one online and see if it would make a good base for a Loki helmet. While I waited for the helmet to arrive I dug up my old Loki helmet plans.
I used them to print out paper templates for the horns.
I used that template to cut out new horns in some insulation foam.
When I finally got the helmet it had a plastic coating on the top and straps.
I carefully removed the plastic cover.
...and I cut out the straps.
Next I used my helmet as a template on more foam to begin making the additional neck/jaw areas of the helmet.
I cut out several layers of this.
Next it was time to glue these pieces together. Ordinarily I used hot glue for insulation foam since no other glues seem to work well. My brother suggested using liquid nails made for foam...
I glued then clamped.
The drying process took longer than stated on the bottle, but at the end of the day it seemed to have worked well enough.
Then I began shaping the horns with my belt sander. This handled the outsides of the horn well.
For the insides I had to use a coarse sanding block.
But it came out well.
Below is a unsanded horn next to the sanded one.
so far it's looking good next to the helmet.
After a short while both horns were sanded.
I temporarily attached the horns to the helmet with toothpicks.
After the horns I began to shape the lower part of the helmet.
Next I used some air-drying clay to fill up the holes in the front where the horns will go.
I made some spaces for toothpicks to go. This will hold the horns in place later while I'm attaching the horns.
Then I glued the sides to the top. I also added a strip of foam to the inside back to fill in the gap and add some extra support.
Then I decided to fill in the other holes in the helmet with clay.
I let the clay dry 24 hours before working on the helmet again.
Next I added filler to the sides to help even it out.
When it dried I sanded.
I added the toothpicks back and glued them in place.
Then I attached one of the horns.
and then the second horn.
Both horns were glued in with quite a bit of glue, but everything held together nicely.
I filled in the gaps and seams with more liquid nails.
When all was dry I made some paper templates for the sides.
I used the templates on some thin crafting foam and cut them out.
Then I glued them to the sides of the helmet.
I put on the helmet and it fits well. It's a little heavier in the front, due to the horns. Later I will even it out better.
Before I can spray on any filler primer I need to fill and cover all the foam. Propellant from the spray paint will dissolve the foam, so I painted on some layers with standard wall/furniture primer and a brush. Since the foam helmet/horns/sides are quite porous, it took a long while to dry.
After several coats the helmet was fully layered in primer.
After a day of priming and drying it was ready for filler primer (from a spray paint can).
When the primer dried I added more clay around the horns and on the back of the helmet.
Next I added wood filler to parts of the helmet.
Then it received a lot of sanding.
Followed by a few layers of primer.
When the primer dried I sanded the whole helmet with some fine sandpaper. I love how it looks. It's smoother, but with some nice texture left behind.
This gives me an idea of how I want this helmet to end up looking....but I will get to that later. Next I added some wood filler to the bottom and sides.
Then I started creating the crest for the front of the helmet out of insulation foam.
I glued it in place....
...then I covered it with cardboard and crafting foam.
Next it received some more wood filler, mostly to the new addition.
Throughout this process I have ignored the inside of the helmet. It's been uneven and bothering me. So I used my detail sander to begin leveling it.
I finished sanding with a sanding block to make it smooth.
I then coated the back with one big piece of thin crafting foam.
Then I added more filler to the bottom & sides to clean up the edges.
Then came sanding....
...followed by primer.
Next I touched up some areas with a little more filler.
Next I made new tips for the horns out of air drying clay.
When the clay dried I sanded.
Then applied the last coats of primer.
Earlier in this blog I mentioned how much I liked the effect of the dark gray primer after being sanded with some very fine sandpaper. It's time to finish this helmet up, and I began with sanding to recreate that look from earlier.
Next I took my gold spray paint and a large brush...
I sprayed the gold paint lightly onto my brush and began dusting the helmet.
This gave a great dirty, gritty look to the helmet.
It took a while to completely get the helmet the way I wanted. The gold paint dried quickly, and I made sure to make many passes with my brush, each in different directions.
The final outcome was more than I hoped.
I let the helmet fully dry for a while before I applied some clear coat.
Once it dried, I tried it on.
Fits well. Still a little heavier in the front, but manageable.
With the helmet done, all I needed was a new helmet stand (the one pictured has become my work stand).
So I bought some furniture legs, plaques and small wood shapes from Michaels and Home Depot.
Assembly of these stands takes about 5 minutes.
Below are my 2 most recent helmet builds with 2 new stands.
I coated the stand in the same dark gray primer that the helmet was painted.
And using the same technique as the helmet, I brushed on some gold spray paint.
And I am done!!!
It feels great to finish this helmet.
I loved my original build, but I feel this one is so much better than my first one.
Thanks for reading!