EVA FOAM HELMET

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INSTRUCTIONS

Step 1 - Print out provided helmet template on A3 size paper. The template is only one half of the helmet. This template will also be used to make the other half of the helmet by flipping it over.

Step 2 - Glue printed template onto cardboard with your choice of spray adhesive, craft glue or glue stick.

Step 3 - Cut out the template with a craft knife or scissors to give you three cardboard templates. Make sure to cut the joint guides like a "V" shape.

Step 4 - Place the cut out cardboard templates on top of 5mm EVA foam and use pearl head pins to hold them in place temporarily.

Step 6 - Trace the cardboard templates to EVA foam using a white marker, not forgetting to trace the joint guides.

Step 7 - After tracing, take off the pins and flip the templates. Place them onto the EVA foam and trace the flipped cardboard templates again using pins to hold them temporarily.

Step 8 - After tracing all cardboard templates for both sides of the helmet, take off the pins and remove the cardboard template. Label all right sides with A, B and C and the other side with AA, BB and CC.

Step 9 - Cut EVA foam by following the outline using a craft knife on top of a cutting mat. (Do not cut the joint guides).

Step 10 - You will now have 6 pieces of EVA foam to form the helmet. Label the pieces with a marker. A, B, C for the left side and AA, BB, CC for the right side.

Step 11 - You need to shape the EVA foam helmet pieces before gluing them. Parts can be shaped using a heat gun.

Step 12 - Heat one piece of the helmet by using a heat gun and press it on your knee to create a round shape. Do the same to the other parts.

Step 13 - Parts can be joined by using contact cement.

Step 14. Join the pieces labelled A, B and C first. Join A and B first. Spread contact cement on the edges of both pieces, let dry until tacky to touch and then join the 2 edges together by matching the joint guides. Start from one end to the other. You may need to pull, push or stretch the foam to match the joint guides.

Step 15 - After gluing A, B and C pieces, you will now have half of the helmet. Do the same procedure to pieces AA, BB and CC to make the other half of the helmet.

Step 16 - Join both halves together from end to end with the same procedure as before. Make sure to match joint guides.

Step 17 - Now you have the basic helmet shell. Smooth out joined edges with sandpaper prior to painting. The helmet can be painted with acrylic paint prior to adding the embellishment.

Step 18 - Print the embellishment template on A3 paper and follow steps 1 to 10 to make the cardboard templates. You can use 5mm or 10 mm EVA foam for the embellishment. The embellishment parts can also be painted prior to gluing.

Step 19 - Embellishment parts can be glued to the main helmet shell by using super glue. You can use pearl head pins to hold parts in place temporarily before glueing.

Step 20 - Get creative with your embellishment design. Try a range of your favourite colours, LED lights or even stickers. Remember that your only limit is your imagination and make sure to always have fun making things!