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Make a Knight Helmet - Out of Craft Foam

This is a fun and easy project that comes out looking good. Even if you don't have a lot of crafting skill you can easily make this project. And I give you the template which makes it even easier for you.

The template is here

This is one of a series of craft foam armor projects I have where I make a complete suit of armor. You can see all those projects here.

YoutubeWill has a youtube channel with over 700 videos on projects you can make. Check it out right here



Here is the completed helmet

Knight helmet


Earn a Certificate of Contribution!


If you make this project email me a picture! I will email you a certificate of contribution from stormthecastle.com You can print it up and hang it on the wall.




Materials and Tools:

Note from Will: The Template and this tutorial is absolutely free! But would you consider a donation of $1 to support my work? Paypal makes it very easy and safe. Click here to donate $1 - Every little bit helps Will to keep making great tutorials and templates. Thanks!


Poster board

Cut a piece of poster board so that you have a piece that is ten inches by 28 inches. Then draw a line down the middle of it like you see here.





Spray adhesive

If you have a spray adhesive go ahead and coat that piece of foam board with an even coat of adhesive.

You can use other types of adhesive like white glue but you really should test it first. Test by spreading out on posterboard then applying craft foam and letting it dry. You are watching for even stick and no curling.






Apply the foam

Apply craft foam evenly and smoothly. And an important thing is to keep the integrity of that center line. Put the edge of the craft foam along that line. We want a break in the foam along that line.







Apply a second sheet

Ok, I am applying a second sheet of craft foam. And for me this finishes the covering of this piece. And I have a nice division right along that center line.






Flip it over and trim the excess craft foam.


Fold it

Crease it by folding it along that center line.









Shape itNow we can curve it into the shape of the helmet. Notice how that folded center line edge is going to be the centerline of the helmet right down the center of your face when you are wearing it.

Shape your piece like this and tape that back edge. You can tape it on the outside of the helmet for ease. But it will look better if you run a line of tape along the inside of the helmet to tape those two edges together.

NextLet's continue with the tutorial (You can also watch the video tutorial below)



Watch the Video Here:



Jacobson Hat Company Men's Antiqued Pewter Knight Helmet, Silver, Adult






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