We’re surrounded by everyday objects that can be used for cosplay, and I love seeing people go off the beaten path for costume solutions. Instructables user WardWorks, a.k.a. Ward, got creative when he made a helmet for his Assassin’s Creed Templar Knight costume and made it from two 18 inch by 24 inch plastic “For Sale” signs. Brilliant. He also used super glue, paper fasteners (as rivets), EVA foam, paint, and a few other items. He studied reference images and used Google SketchUp to create a drawing. He transferred that sketch to paper and used his head measurements to make a pattern; that pattern was carefully cut from the plastic signs. He sanded off all the red paint on the signs.
Here’s how he shaped the helmet:
Use the heat gun to shape the helmet. It should have an oval shape, at least my head and thus my helmet have an oval shape. Your head may vary. The lower face shield should also curve. Heat the plastic, shape it, let it cool, try it on, and repeat the process as necessary. You will need to use a paint can as a form to maintain the shape of the helmet.
Cut a piece of cardboard in a slight oval shape a bit larger than needed for the top of the helmet. Trim it in small increments until it’s the right size. This plate will also help the helmet maintain its shape. Once the cardboard is trimmed to shape, trace that shape onto the plastic. Draw another line .5″ wider than the cardboard template. These will be tabs to attach the top to the sides. Once you cut out the plastic, cut slits into the plastic to form tabs. My tabs were roughly .5″ wide. I heated the tabs and folded them down, using a straight edge to approach a 90 degree angle. Fold each tab down before you begin gluing. The tabs will overlap, and that is okay. Continue to heat form and round the edges of the top. You want it as round as possible for a tight fit when you start gluing.
I glued the first tab to the helmet. I had to heat form potions of the top and sides to ensure a tight fit before gluing. Even after gluing all the tabs, I did additional forming for a better shape.
With the top in, glue the top horizontal band in place. This can also help hide any gaps you might have between the top and sides.
The helmet should have now taken shape. The curves may not be the smoothest, but since this is a battle worn helmet, dents and dings are to be expected.
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