Fantasy Dwarf Helmet

Before I can post this year’s costume creations, I need to do last year’s.

Here are some in-process photos of a fantasy Dwarf helmet I made for Ezra’s costume last year.

It all started with a baseball batting helmet I found at Pittsburgh Center for Creative Reuse, and some chunks of 2×4 I glued into blocks.
I cut the helmet down and roughed out horns on the blocks.
I carved the horns with a spoke shave, and sanded them. They’re bolted into the helmet using large lag bolts from behind, with hot glue to fill in the gap between horn and helmet.
Details were applied using flexible craft foam attached with hot glue.
I sprayed the entire helmet black, and then painted most of it metallic steel. After spraying a protective varnish, I added fur to the horns.
The finished costume included a “wizard” beard that we braided, scale armor made from aluminum flashing that I had when I was a kid, one of many home made cloaks, and a wooden hammer I’ll show off in another post.

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