A Roman soldier's costume is a time-honoured costume for parties and other events. However, because of its status, the supplies for a Roman costume at a costume shop can be very expensive. Making your own Roman soldier's helmet is a viable alternative to buying some of the expensive party supplies at costume shops.
A Roman helmet can be made from many different types of supplies. The easiest form of helmet to make is made from paper or cardboard. For this type of helmet you should have some cardboard, scissors, an X-acto knife, a pencil, aluminium foil, red feathers, hot glue and some brads. If you want to get a little more adventurous you could also get some metal or bronze coloured spray paint. Making a metal roman helmet is a lot more difficult, and should only be attempted by someone who has metalworking experience and equipment. You will need a military-issue metal helmet like those worn in WWI or WWII. You will also need a metal angle grinder, some sheet iron or steel, some metal brads and some leather. You will also need tools capable of boring holes into metal as well as metal cutting tools and leather working supplies.
The paper helmet is easy to construct. You will need a piece of cardboard about 7.5 cm (3 inches) wide and long enough to wrap around someone's head. You will also need two strips of cardboard that will make a cross pattern connected to the headband across the top of the head. Make two pieces that cover the ears, and one final piece that connects to the front of the head band to make a neck guard for the back of the head. Connect the head pieces and the neck guard together with glue or staples. Attach the ear guards with brads. Cover the whole helmet with aluminium foil. Attach feathers and other decorations.
The metal helmet looks very authentic, but is almost impossible for the average person to make. It is made in a similar fashion to the paper helmet, but uses a real military helmet as a base. The helmet is heated to over 371 degrees C (700 degrees F) to remove the modern shaping. It is then shaped to look like the helmet style used by Romans. The ear guards are made from sheet iron or steel. They can also be made from bronze. The ear guards are attached with metal brads. The neck guard is also made from steel and attached with metal brads. Padding is added to the inside of the helmet to make it fit correctly over the head. A leather chin strap is attached to the helmet in the front.