Astronaut Helmets

by JOANN |

Item # 262112220P90
Astronaut Helmets is rated 2.3 out of 5 by 3.
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Intermediate Varies
SUPPLIES & TOOLS:
  • Pattern
  • Cardstock for pattern
  • X-Acto Knife & #11 blade
  • Utility Knife
  • Optional: Band Saw with fine tooth blade
  • Cutting Board
  • EVA Foam Sheet, 20" x 40": 5mm, 1, 10mm, 1
  • EVA Foam Dowels: 5mm, 1, 10mm, 1, 15mm, 1
  • Contact Cement with brush applicator, 3 oz., 1
  • Heat Gun, 1
  • Colored Pencil, light color
  • Mod Podge, Satin
  • Paint: Folk Art, Multi-Surface Satin Acrylic, 2 oz, White, 1 for adult
  • helmet, Baby Pink, 1 for child helmet
  • FX, Flexible Acrylic Paint, 3 oz, Armour Metallic, Silver, 1
  •  
  • Brushes: 1" foam, 1/4" & 1/2" Flat

DIRECTIONS:
  1. Print pattern on to cardstock. Cut pattern for Side and Center, two reverse of each pattern from 10mm EVA foam sheet. Cut one Base Trim and two Side Trim, reverse, from 5mm EVA foam sheet. Use an X-Acto knife to cut. Keep the blade vertical when cutting. Optional: for a clean, vertical cut a band saw may be used on the 10mm foam.
  2. Heat all parts with a heat gun. The foam will change from a matte finish to a slightly gloss finish when enough heat is applied. Start to curve the Side and Center parts to reflect an approximation of the final curves of the helmet.
  3.  
  4. Apply Contact Cement to the “V" cuts in the Side and Center pieces. Make sure to coat all edges completely and wipe off any excess immediately. A folded piece of cardstock may be used to force the Contact Cement down into the points of the “V" cuts. Let dry until no longer tacky. Start at points of cuts lining up the outer flat surfaces. The outer ends of the “V" cuts should line up.
  5. Apply Contact Cement to the center edge of the two Center pieces. Attach Center parts together starting at the front and lining up the registration marks and the seams of “V" cuts.
  6. Apply Contact Cement to the outer edge of one Center piece and the top edge of one Side piece. Attach one Center to Side starting at the front and lining up the registration marks. Repeat for second Side.
  7. Apply Contact Cement to the vertical chin strap edges of Side pieces. Press together.
  8. Attach the Base Trim. Find and mark the center of the Base Trim. Line up the center mark with the center front seam, chin strap, of the helmet. The bottom edge of the Base Trim should lie flush with the bottom edge of the helmet. Use a pencil or a toothpick to mark the location of the trim onto the helmet. Mark 3" from the center seam on the helmet and 3" from the center mark on the inside of the Base Trim. These markings locate areas to apply glue. Attach the first 3" section with Contact Cement. Continue gluing the trim 3" at a time. The ends of the trim should line up at the center back seam.
  9. Attach the Side Trim in the same manner as the Base Trim. Start at the center top. Attach the full circle around the face hole lining up the inside edge of the trim flush with the face hole opening. Trace around trim and attach 3" at a time. Pull both side straps around to meet at the center back seam of the helmet. The circles should cover over the Side panel “V" cut seams. Trace around each strap, apply glue and press in place.
  10. Cut rivets from dowels: 8 @ 1/4" x 5 mm - four for each side trim circle
  11. 5 @ 1/4" x 15 mm - four for face trim, one at top back trim seam
  12. 3 @ 1/2" x 30 mm - one for each side trim circle, one at center back
  13. base trim
  14. Lay the circles in place and trace around each to locate placement of Contact Cement. Apply all dowels. Let dry.
  15. Optional: Use a rotary tool with a drum sander bit to even out the layers of foam around the face opening and the lower edge of the helmet. Apply heat to the edges.
  16. Heat the rivets to prepare for painting.
  17. Use a foam brush to apply a thin coat of Mod Podge to all edges and outer surfaces of helmet. Use a small brush to blend out any puddles that may form. Let dry overnight.
  18. Use sandpaper to lightly sand any rough edges.
  19. Use a foam brush to apply 2-3 coats of white or pink to the large flat surfaces of the helmet and all edges of trim that land next to the flat surfaces. Let dry.
  20. Use a ½" brush to apply 2-3 coats of metallic paint to the top surfaces of the trim and all of the rivets. Let dry.
  21. To fit to individual head, add rectangular shaped spacer stacks of foam inside top sides of helmet. Tape stacks in place to adjust placement prior to gluing. Additional spacers may be placed inside the front center.
CRAFT HACK TIPS & TRICKS:
  • When painting the white or pink to the flat surfaces, use a damp, clean white cloth to immediately remove any paint that may run over onto the trim.
Rated 5 out of 5 by from This helmet is perfect! I looked at many sites and they all ask for money for a pattern. This site give you one for free that I downloaded easily and it is very easy to make with the numbers corresponding. Thanks Joann. You saved us for a class dress up Also very inexpensive to make Does take a few hours tho. Fun hours!!! Thanks so much
Date published: 2022-06-14
Rated 1 out of 5 by from Link not working The helmet pattern link is not working. Project impossible to do without it.
Date published: 2020-09-15
Rated 1 out of 5 by from The pattern url is not valid I want to make the astronaut helmet, but the pattern link is not valid.
Date published: 2020-09-02
  • y_2024, m_8, d_6, h_8
  • bvseo_bulk, prod_bvrr, vn_bulk_3.0.42
  • cp_1, bvpage1
  • co_hasreviews, tv_0, tr_3
  • loc_en_US, sid_262112220P90, prod, sort_[SortEntry(order=SUBMISSION_TIME, direction=DESCENDING)]
  • clientName_joann

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