How to Make a Bobby Helmet
- 1). Cut a 2-inch strip from the poster board. Wrap it around your head and tape the end down. Blow up the balloon until it is the same size as your head. Push the balloon two-thirds of the way through the headband. The top of the bobby helmet must be much higher than the crown of your head.
- 2). Mix the flour, water and salt together to form the paper mache glue. Cut the newspaper into 2-inch wide strips and dip them into the flour mixture. Let excess glue drip off before laying them over the top of the balloon. Do not put strips below the headband. Overlap the strips as you go. Let the helmet dry.
- 3). Cut two equally sized brims from the poster board. The brims form a small peak around the sides, coming to a point at the front and back. Use the newspaper to experiment with shapes until you find one that fits. Carefully remove the balloon from the dried helmet shell. Cover both brim sections with paper mache strips and drape them over the balloon so that they have the same curve as the helmet. Allow to dry overnight.
- 4). Tape the brim to the helmet rim. Tape the brims together at the front and back of the helmet. Cover the helmet and brim with a second layer of paper mache. Allow to dry overnight. Repeat for the third and fourth layers, allowing the helmet to dry after each new layer.
- 5). Wet the felt fabric. Spray the helmet with adhesive and press the felt fabric down over the helmet. Smooth the fabric over the helmet and brim. Pin the fabric to the helmet as you go. Allow the helmet to dry. Spray the underside of the brim and tuck the fabric over the edge of the brim, sticking it to the bottom as you do so. Trim off excess felt.
- 6). Measure the distance from the middle of your chin to the edge of the helmet. Measure the belt from the buckle down the length of the belt until you have a piece that is the same length as the chin measurement you just took. Cut the belt here. Repeat for the other end of the belt, allowing for a couple of inches so that you can buckle the two pieces. These will be used to create a chin strap. You will be left with the center part of the belt.
- 7). Spray the bottom of the center part of the belt with adhesive and wrap it around the helmet where the crown meets the brim. Trim off any excess. Staple the buckle to one side of the helmet. Staple the other side of the belt (the side with the holes) to the other side of the helmet. You can buckle the two sides of the belt under your chin as a chin strap.
- 8). Spray the back of the plastic badge with adhesive and stick it to the front of the helmet.
