How to Make a Helmet Mold

Written by nicole carlin
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How to Make a Helmet Mold
Make your own helmet mould. (helmet image by Goran Bogicevic from

Making a plaster mould is a creative project that both kids and adults will enjoy. Making a mould of a helmet means that you’ll be able to reproduce a replica of that helmet as many times as you would like. You can choose to make a mould of any kind of helmet, but be sure that you protect the helmet by first covering it with petroleum jelly. You can make a plaster cast of plastic, wooden or metal helmets.

Skill level:

Things you need

  • Plaster fabric
  • Scissors
  • Petroleum jelly
  • Helmet
  • Bowl of water

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  1. 1

    Cut 1 inch wide and 6 inches long strips of plaster fabric.

  2. 2

    Spread petroleum jelly over the entire outside of the helmet you will be covering. The petroleum jelly helps to protect the surface and makes removing the cast easier.

  3. 3

    Wet a strip of plaster fabric and apply it to the outside of the helmet.

  4. 4

    Continue this process as you wet and apply the plaster strips to the helmet, working in a pattern so the strips slightly overlap one another.

  5. 5

    Cover the entire outside of the helmet with strips.

  6. 6

    Allow the plaster to dry, leaving the helmet covered for 1 to 2 hours.

  7. 7

    Remove the plaster mould from the helmet.

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