Adam Savage's One Day Builds: Epoxy Headcast Helmet Skullcap!

Adam makes use of one of his lifecasts to make a perfectly fitted skullcap for his Iron Man Mark I helmet. It'll require laying down epoxy fiberglass on top of the lifecast, padding it with neoprene, and then sewing a leather liner to give it a welding-jacket aesthetic that fits inside his Mark I's flip-up helmet. And keep an eye out for a special appearance by Adam's dog Maggie!
Watch the full Iron Man Mark I build (so far) here: bit.ly/3nV1pYn
Shot by Adam Savage and edited by Norman Chan
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Intro bumper by Abe Dieckman
Thanks for watching!

[@tested]

Watch the full Iron Man Mark I build (so far) here: bit.ly/3nV1pYn

[@broadstken]

Check out "Finnish M40/55 Helmet Liners" on Ebay they're cheap and would probably be a good fit for almost any helmet project

[@VAXHeadroom]

Adam should TOTALLY do Merlin from Excalibur cosplay!!

[@Xiph1980]

Hi Adam, Norm, and everyone there at Tested. I assume Right to Repair is close to your hearts as makers. Louis Rossmann's movement is picking up steam now, and lately a few other channels like Linus Tech Tips, and Marques Brownlee (featuring Simone! 😊), have made videos about it too. Would it be interesting for you guys to cover that too?

[@pacificcoastpiper3949]

When Adam wore the masking tape cast as a hat I almost swallowed my chaw from laughing so hard! Especially when he wiggled his eyebrows

[@willmfrank]

@@pacificcoastpiper3949 When he drew the letter "A" on it, I said, "Now he's Captain Adamerica."

[@TotalBoat]

Adam! The clear epoxy we sent you IS our boat epoxy!!!!! High Performance epoxy is the BOMB for making things clear and strong and yes - even for boats and heads and skull caps. We will send more! This was epic... almost!!! hahaha.

[@mattbaumgart3621]

My 5 year old son just watched a good portion of that video with me because he loved seeing a boy wearing costumes and using a sewing machine. As someone who is not creative, he’s only seen my wife use it. He now wants to build a baby yoda costume and when I introduced him to the concept of a convention he says he’s going to wear it to show everyone. So feel free to envision a 5 yr old wearing a home made Grogu costume at a convention to brighten your day.

[@tekvax01]

Parenting done correctly! Achievement Unlocked +1

[@ericgordon342]

I will help make this a reality, the child shall be the child

[@Haslop]

How did it go?

[@yig_501]

so adorable XD

[@NanaVonn3]

Two things: 1. I would totally watch a build of Adam customizing his sewing machine! I have a Brother Luminaire 2 (which I would never dream of customizing beyond removable vinyl decorations), but I just got a 1973(ish) Premiere industrial machine that I would like to play around with ($25). 2. This is why I love watching Adam's videos. I never would have thought to use WonderClips as pins in this situation... I've used them instead of pins for bamboo lycra before, but never for tailoring.

[@SaiyanQueenVega]

Maggie is just so darn adorable! It always feels like a special treat when she gets screen-time...

[@pobbrett3244]

Had to laugh at Adam improvising the skull cap pattern whilst wearing the perfect masking tape pattern throughout.

[@MarcDavison01]

i hurt me so much, i was like "Adam you fool, just cut your masking tape cap into a flat pattern and replicate it onto your leather liner!!"

[@RogueCloneTrooper]

It would have been so much quicker if he had used the masking tape cap as the pattern. But each to his own… and that was the long and painful way…

[@sanityormadness]

But then he wouldn't have his masking tape cap any more. Priorities! 😛

[@alicemasters2539]

came here to say this exactly.

[@ivanparas]

My first thought when he showed the intact tape layer was "Great, now he has a pattern for the liner".

[@mjmmjm9299]

You had the perfect sewing pattern already. The tape hat.😁

[@user-ee9cz6mc1x]

Was looking for this

[@halyenwe]

Yes! My mind was thinking baseball cap pattern but this is even better. Hopefully Adam reads this.

[@qUICK3558]

In my head I was telling that the whole time hahaha

[@lujho]

Exactly! Just cut it up and trace it.

[@anthonyroberts7850]

Yessss good pick up! I didn’t even think of it, but in the back of my mind I was thinking there has to be a better way 🤣

[@hadinossanosam4459]

Love the goofy-Adam mood in this one... talking/singing whatever while he's sewing, filming the throw in the garbage can, tapping out half a drum track on the cap Also creative filming with the shot of dropping the cutoffs (55:45) and then the resolution at the very end of seeing him cleaning them up

[@peckenstein]

"Wow my hair is crazy" *Literally makes it stand up more* "Yeah, that's better" Seriously the best! Adam, don't change!!!

[@chrissimmons4503]

It’s been far too long since we’ve had a Maggie intermission ❤️🐶❤️

[@shubinternet]

I love how we get audio that may be out of sync with the time lapse portions, but still accurately reflects what is going on during those portions, and then how it re-syncs when the time lapse stops. Sometimes you almost don’t notice that the audio is actually out of sync with the video and then you wonder how they sped up the visual part but kept the audio at normal speed. Kudos to Gunther!

[@NirateGoel]

I love these ODbs with Adam's madness in them, the camera crewed ones don't have the same madness or life to them.

[@whalestorm7354]

I demand more goofy Adam. This One Day Build was very fun and entertaining to watch!

[@NirateGoel]

One of the best parts of the self-filmed stuff, other than the better camera work....

[@RealAndySkibba]

Pretty sure Botal Toat sponsors at least 95% of DIY projects on KZbin now.

[@JanTuts]

Almost none of which are boat related :D

[@BrianSantero]

Operation: Total Tube.

[@brandonconway4822]

@@JanTuts tbh i think the majority of their non commercial customers aren't building boats anyway.

[@tristiancorbett8896]

Third coast craftsman did build a boat with there resin

[@hoppend]

Can’t beat Gratis!

[@relixofwar]

53:18 needs to be added to one of the one day builds funniest moments. I love it!

[@feather-duster-cat4307]

Manic Adam is my favourite Adam 😂 the random interludes of madness make my day

[@SP_3333]

Omg. You, sir, are endlessly entertaining. Mad scientist (the hair) with a sewing machine & a pirate shanty. Never change. Thank you. 🤟

[@BoojayDeeth]

I like the floor cam with all the cut scraps dropping. I was hoping for a visual gag - a finger, or two. I have been spending too much time indoors.

[@HolographicSweater]

haha i love the "auteur" shot where it shows his feet with a bunch of scraps falling down

[@Vickie-Bligh]

Love this whole thing. I love your 'making up ad copy' in your head while working, I make up songs while I work. This was fun and it felt, even more than other builds, like I was with you in the Cave. Thanks. Great editing, Norm.

[@legomotionz]

Never have I felt more in the right place than watching Adam sing Wellerman whilst sewing a leather cap.

[@spagsketti]

Adam is looking more and more like a mad scientist as his hair grays and gets longer. Totally fits him in every way.

[@chrismorris1304]

I was happy to see Maggie again this weekend! I honestly got worried earlier this week that we haven't seen or heard about her in a while😓 I love these kind of sit-in explorative sessions! Also, great creative ending👍🏼 gives a great sense of closure and completness

[@NewMessage]

"I'm gonna keep doing this until it looks cool!" My High School motto, right there.

[@BooN877]

Whenever I see a life-sized Han Solo in carbonite, I like to imagine that it's the canon conclusion to Empire. That he just ended up in someones shop as a decoration, lol.

[@tekvax01]

That is toooooo funny! :) I sorta thought the exact same thing! He should add lights and sound to it!

[@emmapark8530]

Love seeing adams little assistant maggie

[@bakko9302]

I have used the adjustable liner from a construction site hard hat in the past. Its great, fits like a glove and is super comfy!

[@kristoflemp7331]

Adam singing and sewing is awesome!

[@brandonyoung-kemkes1128]

Thanks for the safety tip. I’m around a lot of resin and I actually in fact didn’t know that. I will most definitely be wearing a respirator from now on.

[@DavidLindes]

43:19 - for what it’s worth, I would absolutely love to see a one day build for adding a knee lift!

[@brenxbux]

One thing I dont think many people praise Adam for is his attention to safety. Its one of those less glamorous details that other DIYers may or may not include.

[@karm65]

stares at the tape skull cap thinking i would cut and use it as a pattern for the liner

[@ericgordon342]

Never, it is now the safety helmet and noone will ever ruin it

[@dylanw.4533]

Taping all the way around your own head to hold the leather in place while you’ve got a 1:1 cast of your head right behind you: That’s commitment to a craft.

[@christopherharrington7337]

I like the floor shot, different and interesting. More Maggie please! How about a one day walk video with Maggie?

[@jackphoton]

"That's how you get epoxy over your scissors and the rest of your life." lolz too true

[@assassinlexx1993]

A flat tray of acetone is great for dropping in the scissors. To save them from frozen dead.

[@shawnbassplayer]

Welding Helmet Ratchet Strap System. Look at something like the latest Miller infinity helmet strap systems... they’ll work great for holding your helmet securely to your head. Strong and lightweight!

[@ericgordon342]

I can literally get him the same thing fire helmets have, i think we actually have one in the gear storage room at the firehouse i volunteer at

[@ladylilithparker]

Adam cuddling with Maggie made my day.

[@aziraphalesshop]

@7:59 all the stagehands start excitedly pointing and saying "Hey, that's dancefloor tape!"

[@anthonymckay5568]

I did exactly that

[@-MrFozzy-]

Hooooow lovely is Maggie?! Such a cute pup!

[@stevenmack9594]

I love how incredibly precise makers can be about many things and then sometimes its just a rush to get the dang thing taped to a stick

[@Games_and_Music]

I was actually going to ask where Maggie has been, hadn't seen her in like 6 months, but there she is :)

[@Stenlynatoroidum]

Exactly !!

[@blee5268]

Maggie's gonna get some big time appearance royalties from this channel!

[@Psycoticlese]

okay but Adam's hair at 20:26 ...Iconic.

[@cheffrin3751]

One of best parts of this whole video is the inside look at what ADD looks like. You started talking about the sewing machine and I'm over here forgetting what you're doing and imagining the system in which you can use your leg for the presser foot. I'm right here with ya dude! Haha

[@tekvax01]

Adam is channelling the _"seamstress reboot"_ of the old ABC show *Cop ROCK!* _As he breaks into song whilst sewing his heart out! :P_

[@tekvax01]

(50:06) Givin' Maggie the shop Dawg some love!

[@hornet65]

The UV cured resin used in 3D printers will also accumulate in your body, and so you should be wearing a respirator around your 3D printer as well, if it's not well ventilated.

[@prolific9002]

Adam, check out top end welding masks. Circular tension dial at the back. You just reinvented the welding mask. Custom fit!

[@CaseyStreet2]

I felt the satisfaction when that cap fit so snugly on your noggin! I love the long One day builds because I can put them on while I model my 3d prints.

[@simonwhite1909]

Wow Adam, Sea Shanties, Janice quotes from Friends? Maggie intermissions. Makes for a strange Maker vlog🤣

[@Super-dupers]

The cast makes the very best little spoot noise as it comes off. Perfection!

[@christophersz]

THE GROOVE TUBE! Damn, I was waiting for the finish, I wondered if you’d give yourself the big sideswipe. Stay safe and thanks.

[@seanconlin8712]

Adam I really want to thank you for showing the young and upcoming makers of the world the proper way of doing things...the safe way. If you wear the proper ppe they will emulate the ways of the person that inspired them.

[@seanconlin8712]

@TerraTN the mask did have both cartridges the one side just didn't have a outer cover on it

[@potzorbie3120]

I loved the Chevy Chase reference at 49:52!

[@markbyers9762]

Adam. Im watching this to the end. You are a crazy person. Maggie knows this

[@blvckplays8971]

I saw online yesterday someone has brought out serrated packing tape. No more needing a blade, you just rip at whatever length you need and because it's serrated it rips perfectly every time.. No more needing to hands to release the tape you need

[@JLOFlix]

This is always FANTASTIC to see, THANK YOU, Adam! Could you PLEASE demonstrate how to create your resin head that I assume that you can sculpt on!! I have a lifecast of myself, but, it's make out of an unbearably heavy ultracal and I need to replicate my head from ultracal into a manageable fibreglass resin bust upon which I can sculpt! I've had a heckuva time trying to find any tutorials on that process! Whatever you can share is welcome! Thank you, Maestro! You're the BEST!!

[@gannibootis]

The most literal application of "headliner" adhesive I've ever seen

[@n3cron99]

I have. To say props to the editor/s the time lapse with normal speed sound that they have started doing is awesome. Best way I’ve seen to show time laps. Very pleasing for some reason

[@tomhorsley6566]

I liked the floor level camera while watching trash get discarded (then swept up at the end).

[@opusBillTheCat]

This machine is SEW amazing!

[@ChloetheGaymer]

The end result is to satisfying

[@JustaMuteCat]

Friend of mine opted to gut and use the internals of a safety helmet and used clear neck/chin straps, then attached it to the inside of the costume helmet using strong, small rare earth magnets sets in a sort of quarter sphere lines that would go from top of the head to the back. That way all he had to do later was to line up the magnets and adapt the internals of any helmet costume he would use to it. Alternatively he told me he experimented a bit with those line-up on/off magnets in the lower back of the head to use them as a main fixation point of the helmet so that the small ones would be just to center it, while the weight bearing would sit in one place only and would be just a matter of lining them up with its switch to be able to remove it. Only issue he had with the later, aside of the expected awkwardness of trying to flip the one he bought with thick gloves were that the commercially available ones were either too small to be useful or too big to be practical.

[@jammin32j]

There is an easier way to apply the fiberglass in the future. Lay all your fiberglass out on wax paper and pre-wet it. It lays down a lot easier and is a much cleaner finish. And if you want to save on weight, you can take a paper towels and soak, some of the resin back out. Awesome job.

[@GrahamGibby]

I have not laughed so much *with* a Tested video in a very long time.

[@MaxMoloko]

That scull cap from masking tape could be cut up as a pattern for the lining. I made slippers that way, just taping my feet and cutting up the tape so I got the flattest piece with the least amount of seams in the end. Also drill some holes in that fiber glass for ventilation. It won't do much, but it will help.

[@NEarlTavella]

Best episode eveeer! Maggie is just the sweetest lil pumpkin

[@justpassinbyy]

47:06 when you realize the voices in your head are all wanting equal air time.

[@mattk7795]

I want the black jacket & Savage meatball patch! If you add them to your merch you would make me a happy man!

[@edburdo]

I started to watch this for the One Day Build. I stayed because of Adam's Antics! - And the Camera Man antics :P

[@clearstream67]

Wow... Adam is in rare form today... Always great to see Maggie.

[@federicon.5085]

This ODB has everything! Friends, Maggie, Iron Man, Sewing, Crazy hair, fake Adam Head

[@LMde20]

Reckon your triangles will be more necessary for ventilation than shape. But, I guess that depends how long you're going to wear it at a stretch. Pretty hot in there. Thanks for the vids Adam. Entertaining and informative, even when I'm not building.😁👍

[@BenjaminVaterlaus]

the captain america A on the gaffer tape was the best. made me full laugh.

[@TheeGrumpy]

Needed a reprise of the sea shanty while sweeping.

[@ericw1355]

every damn time i look at the video length when i start and say to myself damn this one is over an hour long...and every damn time it ends and i think what the hell, because i feel like it only took 10min to watch because i was so fascinated

[@skcamerican]

You could cut the green cap into a flat pattern for the leather. I had a funny-shaped dog that I could never get a sweater to fit, and finally I made a tape-and-newspaper sweater over his weird body, and crocheted that shape. Strangest looking dog sweater you ever saw, but it fit him perfectly. RIP Jeep, you good boy. Not suggesting your noggin is oddly shaped or anything, but it is a complex, curved shape.

[@ShotgunAU]

Seeing Adam in that green tape cap is my fav thing of 2021 so far

[@ToddTevlin]

When he put the masking tape hat on and wiggling his eyes, I was getting some heavy "Cabbage Head" vibes from Kids In The Hall, lol.

[@trevorfulcher4070]

You are the real life embodiment of all of Tony Starks best qualities

[@edix1673]

10:21 did Adam just do a Geordie accent?! ❤️❤️❤️

[@BlueLightSpecial2023]

At 3:30, it looks like Adam got a little a"head" of himself. :-)

[@scotmartin4460]

I was a big fan of your dads, and I've followed your career, joyously. Cheers, dude.

[@stevesmith1764]

Greetings to you too Mr Savage

[@jasonpardoe1825]

Adam, Adam, Adam....Lol, perfect pattern on your head mate.

[@FifthConcerto]

Suddenly I can picture a quarter century from now, a collection of people like Adam Savage making videos in shops on how to make relatively (for some value of "relatively") inexpensive Iron Man helmets that are actually battle worthy. Maybe that's where Hacksmith is going?

[@EnergyWell]

Being forced to watch 2 inserted adverts every three to five minutes makes long content miserable to watch. Love your videos Adam. You are an inspiration!

[@kimmipops5143]

Spooky how the head moves a little by itself on the table from time to time 🙈👻 Keep up the great work, Adam 👏🏼😊

[@curiousfirely]

I chalk that up to the editing, and I'm here for it!!

[@SteveBakerIsHere]

At 36:00 - definite and conclusive proof that you can never have too many clamps.

[@SuperNovaSirius]

"I am Iron-Man." Hihi. Cute. Fun build with yet another chaotic video. Love it.

[@digitaldobbie]

Top Tip: once you have finished mixing the epoxy, don’t lick the spoon!

[@suyeshshrestha2617]

Learned this the hard way

[@ericgordon342]

Can confirm, epoxy is not nearly as tasty as brownie batter, learned the hard way

[@barryrott726]

Anyone else think Adam’s head cast looks like Jamie hyneman when he’s putting resin on top

[@johnpratt1661]

at about 10:42 the head cast moves by itself. Must be haunted, LOL!

[@tearingpluto2636]

Maybe add a couple small magnets to the top hinge to hold it open? Strong enough to hold it up when moving and looking around but weak enough to drop the front when you flick your head

[@ColdIronHalo]

That hair scream FOR SCIENCE !!!!

[@calebmcdowell6255]

i would have loved if there had been a mini build of a knee lift for the sewing machine mid one day skull cap build

[@wakjagner]

49:43 when the year+ of madness finally breaks through.

And here I am yelling at the screen: "Use the tape cap as the template for the padding!"

[@identifiesas65.wheresmyche95]

10:42 - the skull moves 😱

[@Chris-lk3fq]

Adam: first, huge fan. Love and appreciate everything you’ve done for the worlds of science, crafting, cosplay, all of that. Nothing but the deepest respect. Seriously. You are amazing. Thank you for all your many contributions. Now, having said that, sometimes I can’t watch your ODBs. In this video, at about the 36 minute mark, you decide you are going to sew your leather into your skull cap thing. ...and sitting right next to you, THE WHOLE BLOODY TIME, is a perfect model of your head in masking tape which could be easily cut up into a pattern for your leather. Sometimes you make me scream at my television, buddy, and I scare my family when I do that. But again, let me just say that I truly do love and appreciate everything, and it’s a LOT, okay? All the many, MANY things you have done to make science fun, to make crafting “cool,” to make cosplay accessible and not “weird,” all of that. Thank you from the bottom of my heart for that. ...RIGHT... THERE...!!! Never mind. Keep up the good work.

[@Chris-lk3fq]

God, you even put it on your head...

[@ethobbyshow]

27:40 Adam makes his full transition into the Hyneman

[@ericgordon342]

Wheres the walrus moustache?

[@ethobbyshow]

@@ericgordon342 in a later evolution, still to come lol