How do I Make Metal Knight Helmets?

Written by max quigley
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How do I Make Metal Knight Helmets?
(helmet image by Vladislav Gajic from

Knights' helmets reached their peak in the 14th and 15th centuries when countless variations and designs graced the battlefield. Some of the Teutonic Knights helmets, for example, had massive horns sticking out of the sides with feathers attached to them to give the knight a more frightening, imposing look. These helmets were short lived, however, as the discovery of gun powder would soon make them once and for all redundant on the battlefield. The helmet described here is a medieval bucket helmet, but much of the same process can be used to make other designs.

Skill level:

Things you need

  • 2-by-1 foot sheet metal
  • Hammer
  • 1-foot diameter log
  • Drill
  • 1/2-inch drill bit
  • 3/8-inch drill bit
  • 1 ½ -foot circular sheet metal

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  1. 1

    Find 2-by-1-foot sheet metal. 0.05-inches thick is perfect. If it is an old sheet you may need to sand rust off. Use an angle or a belt grinder to do this.

  2. 2

    Hammer the steel into shape. Using a round log or piece of wood with a 1-foot diameter, bend the sheet steel around it so it takes a circular shape. You can use a hammer to aid you in this process as doing it all by hand would be extremely difficult. The steel should now be in the shape of a bucket except without a base at either side.

  3. 3

    Bolt the ends together. Once you have achieved the 'bucket shape,' bolt the ends together so it stays in that shape. To do this drill three or four 3/8-inch holes at identical places on both sides of the metal helmet and overlap the two sides so that the holes are on top of each other. Now bolt them together using a nail that fits the hole size. To bolt them together, simply slide the nail through the overlapping holes and hammer the nail point so that it does not slide back out.

  4. 4

    Attach the top of the helmet. Using a power jigsaw, cut out a circular piece of sheet metal 1 ½ -feet in diameter. This will fit on top of the helmet. Allow the top to be a little larger than the circumference of the helmet itself. This is so that its edges can be lapped over the edge of the helmet, allowing for it to be more easily secured. Bolt the overlapping edges to the helmet in the same way you bolted the ends together.

  5. 5

    Drill eye holes and air holes into the front of the helmet. Use whatever sized drill bit you like and then use hand files to form the holes to the exact dimensions you desire.

Tips and warnings

  • Using power tools is always dangerous, so great care should be taken when using them especially if this is your first time using them.

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