Zipper Cap >>> High Priest Helmet

I showed the zipper cap to my assistant and she immediately said it looked like a bathing cap from the 1950's. I about died, because I knew she was spot on, and that wasn't the look I was after.


After a bit of thought I decided that if I added a military type neck guard it just might rescue the project from ignominy.

It was important that I kept with the non fastener method of assembly, and so I pondered how I could make the neck guard flaps interlock with the cap I already had. By repeating the lower edge and constructing mountain tabs to interlock I arrived at the pattern shown above.

I dyed the nine neck guard pieces in matching colors and assembled them in groups of three.

And here is the result. After assembly the entire helmet was antiqued black to give it an aged look.

I'm pretty happy with how it turned out, and this model really gives it an other culture look.

Halloween is Over

All right, not really, but our crazy Halloween season is just about. Besides my wife's and my regular business of resin casting, we have been selling leather masks on Etsy, and these last three months have been inordinately busy. And while I'm grateful for the income, I am so ready to slow down and and take it easy. You may have noticed my lack of posts lately, which is totally due to my having very little time to work on new projects.








My skull respirator, for instance, has been almost complete for about two months, but is still unfinished. I expect to proceed with it soon. I have decided to pair it with a blue fire helmet that I made long ago, but never made a plate for (the decorative piece on the front).






For the red Firemaster helmet I made the plate out of leather that was embossed and gold leafed.

For the blue fire helmet I plan on making it out of cold cast aluminum, the same material I used for the Sentinel plate, shown above.

The helmet and respirator together will be the official gear of an elite cadre of firefighters: The Death Defiers. Their motto is "Death to fires!" This is of course a play on words, as the two sound almost identical when spoken. My plan for the plate is a smaller, flatter version of the skull on the respirator (shown above), surrounded by the name on top and the slogan underneath. I am excited about seeing it done.

Defender: Helm is Complete!

My color scheme for the Defender has been black and silver from the beginning, and now I can reveal why I chose silver. It was all based on this wonderul silver colored horn which is now mounted on the left side of the helm, to assist the wearer in detecting sounds. An auditory amplifier.



The black color was chosen because the last two major pieces I created were both brown, and I wanted some greater variety. The helm is now complete (except for the satin liner which will finish off the interior). I do still have more to do on both the mask and the gorget.

Defender: Helm with Plate

Today I attached the plate onto the front of the steampunk Defender helm. Not a lot left to do now. Mostly things that don't show.

Defender: Attaching the Aether Collectors

The Defender steampunk helm is getting ever so much closer to completion. Today I added the ten luminiferous aether collection devices.



After riveting the devices to the neckguard trim I stitched and riveted the trim to the neckguard itself.



I then antiqued it to match the rest of the helmet. No more bright colors!



Here is a detail photo of the rear of the helm, showing the crest and the aether devices. Next I will finish and mount the front plate.

Defender: The Aether Collector

Here is the working part of the Defender helmet: The luminiferous aether collection device. The neckguard will have a bank of ten of these little beauties.



Luminiferous aether is the substance which fills the upper regions of space beyond the clouds. It is the medium which allows light to travel. The luminiferous aether collection device was designed to gather the energy from the aether and convert it for personal use.

Defender: Starting the Mask

With the helmet nearing completion, I have begun on the mask. These two parts—the helmet and mask—could be worn alone, but they are designed to be worn together.



This is a variation of the gas mask, with two respirators on the sides of the snout replacing the single central one, which gives it an eerie alien look.



Each of the two eyepieces will be different. One of them will resemble a camera lens, and the other a porthole.



Here is a photo of the mask after the major leather pieces have all been stitched together.

Defender: Antiquing the Helm

I went ahead and riveted the crest to the helm, and then antiqued it all black. The purple and red now remain only as highlights, just the look I was after.



I've been building the luminiferous aether collection devices that fit into the neckguard trim, and I can't assemble that until they are all cast.



Meanwhile, I have started on the headlamp. Here is a photo of the lamp as I found it at a yard sale. I will break it apart, and then the lamp will attach to the front of the helm.

Defender: The Neckguard Trim

I will be adding a second layer of leather over the bottom edge of the neckguard, in order to reinforce it and make it lay smoother. If I make the trim the same size as the neckguard, and stitch them together, the resulting piece will want to lay flat, which I don't want. The neckguard should roughly form a half circle. In order to get it to readily make that shape I will make the trim piece longer than the base piece.

If you take two pieces of paper—one slightly shorter than the other—and fasten the ends together, it will bend into a curve. If you wrap tape around a tube, and keep adding it on over itself, the tape will build up in thickness, with the circumference of each turn being slightly larger than the previous one. Drafting a pattern for the neckguard uses the same principle.


I can make the patterns in paper, and bend and measure them to find the right size differential, but that won't be accurate for cutting it in leather because the leather is thicker than paper, and thus needs a larger differential. Add to that the fact that vegetable tanned leather—which I cut and stitch while damp—will shrink while drying, and I can only guess at how long the trim should be.



Here is the neckguard trim piece after cutting and dying.



And here it is tacked into position. The oblong openings will hold luminiferous aether collection devices.

Defender: Coloring the Helm

I reworked the helm pattern by enlarging it all over, plus eliminating the center crown strip. The fit on the form is good, although it could have been a scoutch smaller. I also went with a firmer leather. In general leather is described by what animal it comes from, its thickness, and its stiffness. The latter quality being mellow on one end of the spectrum and firm on the other.

My first undersized helm was made of a rather mellow leather, because in the 5-6 oz thickness I wanted to use, that was all I had. Once I realized I would have to remake the helm I ordered a side of cowhide specifying that it be firm. Consequently the new helm is not so floppy as the first one was.

I will be making the helm and accompanying mask predominantly black, but I want a few highlights of red and violet showing through. The first step is dying those colors, shown above.

Defender: Designing the Crest

I decided before I remade the crown and neck guard of the helm I would work out the crest, as it plays a prominent role in the helmet's appearance, and could affect how I should redesign the other parts.



This sketch shows my original concept. The helmet—once it was made in leather—really had a samurai feel to it, and no longer looked straight out of Star Wars. I feel that the crest simply adds to the Asian flair.

I used the green paper to work out the pattern of the interlocking leather pieces, then cut and riveted them in leather as seen here on the prototype helmet, in approximately the final position.

Defender: Sewing the Helm

I spent many hours both yesterday and today handstitching together the Defender helmet parts with waxed thread. Alas, it turned out to be too small for the plastic form. I cut and sew the leather wet, and when it dries it shrinks, so there is a certain amount of guesswork involved in making the patterns.



For this helmet, the form is important because the leather will be stretched around it to get its smooth shape. Unfortunately I have decided it will be better in the long run to start over again by enlarging the patterns. The other option would be to cut down the form, but that risks destroying it, and rendering all my efforts for naught.

Defender: A New Steampunk Helmet

Time to start a new steampunk helmet/mask. This one has a working title of Defender. My last project—the underground explorer helmet—was met with much critical acclaim.



Since it started with pulling a pattern from a simple toy helmet, I have decided to use the same technique for the Defender's helmet. This time the form is a Darth Vader plastic helmet that I found at a yard sale.



Here I have covered half the helmet in two plus layers of masking tape, and marked with a felt pen where my seam lines will go.



These are the two patterns cut off of the helmet and laid down flat on cardboard. Next I will adjust these pieces so that they will work in leather, then cut the leather and handstitch all four pieces together.

Underground Explorer: Oxygen Canister

I have had a good response to my writing competition. Seems like there are a lot of writers happy for an excuse to create a short steampunk story.

The final piece of the undeground explorer helmet is the oxygen canister which connects to the leather snout. Pictured below is the antiqued canister with rubber tubing and the connection at the other end.


Still to construct is the leather strapping which will allow the canister to be worn on the back or over the shoulder. Brownie points to anyone who can identify the original item from which the canister was made.

I leave for Maker Faire in San Mateo, CA exactly one week from today, and the finished helmet will be the centerpiece of my display.

Underground Explorer: Goggles

With every additional piece (snout, comb, lamp and goggles) added to the helmet the weight increases, and along with it the pressure applied from gravity. At this late stage of construction I know of no way to stiffen the leather itself to better support this weight, and so I decided to build a fiberglass inner shell.


Since the original plastic astronaut helmet is made out of poyethylene--a rather slippery synthetic--I figured I could make the fiberglass directly over it. I took a piece of 5" wide nylon stockinette and it just stretched over the plastic helmet. Then I saturated it with polyester resin and after curing I had a thin strong form that matched the inside of the Explorer's helmet.

I cut the fiberglass shell in half, removed it from the form, and trimmed it down to fit my leather helmet. Above you can see it being contact cemented into the helmet.

Next I attached the recently completed goggles, which can easily be removed. The photos show it with the optional snout removed, so that we can see the face inside.

Underground Explorer: Designing the Goggles

These giant sized paper glasses are my beginning attempt to work out the pattern for the goggles. This is going to take a lot of trial and error to get it right.

Underground Explorer: Lamp Comb is Finished

After focusing on the whale tooth for awhile I have returned my attentions to the Underground Explorer's helmet. Yesterday I reworked the comb pattern and remade it to fit properly, then I cut out the leather and hand-stitched it over the acrylic comb form. Today I painted it black, and antiqued it brown to give it that old look. After drying, I bolted and riveted the comb to the leather helm, and attached the lamp to the front.



I have decided on all of the design elements of the helmet, and have just two more to complete: The eyecover/goggles, and the oxygen canister which will hook up to the snout. With this equipment our intrepid explorer will be protected from extremes in pressure and temperature, as well as falling rocks. They will also have a bright light to see what lies before them, and have a fresh supply of oxygen to weather the pockets of foul air. Hopefully this will protect them from all unforseen dangers that might lurk ahead.

Underground: First Comb Attempt

I constructed the helmet comb out of leather and it has some problems, the major one being it is too small once the wet leather shrank.


Although I will have to remake it this picture gives a pretty good idea of how it will look. Of course once the lamp is mounted onto the front it will change again.

Underground Explorer: Building the Lamp Comb

Our underground explorer is certainly going to need a light to see where he's going. Last year at a yard sale I acquired an old physician's head lamp. Nowadays these head lamps have LED's for the light source, but this one has a bulb, and three multi-jointed arms which allow it to crazily point in any direction. Very mad scientist looking. I've decided to mount this lamp on a comb (also called a crest) which is on the top of the helmet.


Today I designed it and cut out the pieces of the comb in ¼" thick plastic, and then glued them all together. Above you can see the individual parts.


And here is the assembled comb bolted to the top of the plastic astronaut's helmet. I will be covering the comb in molded leather, and the lamp will attach to the front vertical surface.

Space Helmet to Underground Explorer

The poll is over, and Underground Explorer won with exactly 50% of the vote. So I must prepare our courageous traveler for whatever conditions might await. Darkness of course, and probably heat, maybe pressure, foul air, unknown creatures, etc. Thanks to everyone who voted.