How To Make a Foam Helmet Tutorial (Part 1)

I'm the Evil Ted who makes props and costumes. I’ve worked on Star Trek Into Darkness, Walking Dead, Fifth Element and Guyver, among lots of others. I've made pretty much everything out of every material, but foam is my favorite.
I'm here to share my skills and shortcuts, and help you learn how to make foam costumes and props, too.
To see more, check out my site: eviltedsmith.com
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[@XCyclonusX]

FINALLY A real tutorial. 30 seconds in I subscribed. Thank you thank you thank you. You are AWESOME!!!!!!!!!!!

[@EvilTedSmith]

XCyclonusX Thank you for subscribing.

[@flemingtonsaddleburger4918]

This tutorial is so specific. This is a gem to find, most tutorials leave out details assuming you know what to do. Plus you give awesome tips and tricks from working with it for so long. Believe me this does not go unappreciated.

[@EvilTedSmith]

Thank you so much.

[@MerVidiuMII]

"If you don't have duct tape in your house you're insane!" aah this guy

[@bethor18]

Sir Evil Ted My daughter took me to my first Comic Con (in Phoenix), and when I saw all those fantastic people dressed up in their costumes and knew I wanted to give it a try at least once. So, the first material I was told to use to make good costumes was Warbla…and then I saw the price. That’s when my wife came across your video on how to make a helmet and showed me…Sir you had me at EVA foam. Your tutorials and shipping lists have made my new hobby so much easier to start. So now when the Phoenix Comic Con rolls around next year, not only will I’ve turned 50 years old, I’ll be in a costume of my own design all thanks to your help. You rock Sir Evil Ted!

[@EvilTedSmith]

Welcome to the mid century club… Your story put a smile on my face. Please be sure to post pictures of your outfit. Sir not so Evil Ted

[@bethor18]

The wife's so happy I've chosen this hobby to focus on for my "mid life crisis" and not something useless like a sports car...Lol. Absolutely, I'll post the pics to your Facebook page when it's completed. BTW, great job working with those kids and showing them how to use their hands and minds to be creative. If just one of them picks up this creative craft and builds something in the real world, and not sit in front of a video game for hours...then Sir Evil Ted, you've done a fantastic job. I plan to include my Grandson as I go down this adventurous rabbit hole. Lets see where it takes us...

[@jonathanvargo9041]

New favorite quote: "If you don't have duct tape in your house you're insane!"

[@Wowzerfish555]

That laugh when you mentioned the rubber gloves reminded me so much of my doctor... You're great. This video was rly helpful thanks XD

[@EvilTedSmith]

Thank you PluralGam3r

[@randyfoster1949]

I've recently began, awkwardly, learning to make EVA foam armor. After watching many tutorial videos I must congratulate your effort and thank you for making the best I have seen yet.

[@EvilTedSmith]

Thank you Randy. I'm going to do my best to make them better as I go.

[@randyfoster1949]

Evil Ted Smith I wanted to ask you about the Barge glue you are using. I have seen others post about this, but saying they no longer used it because of recent formula changes making it less effective. Are you using the 'new formula' with success?

[@jasonsoares326]

Ted, I finished my first cosplay and it all started with this video. Thanks man!

[@EvilTedSmith]

I'm happy to help. Thank you for subscribing.

[@juanagarcia1811]

I was so going to give up on trying to making fake foam armor and helmets, because out of all the videos I've watched they were to COMPLICATED but you help in a big way :)

[@EvilTedSmith]

Thank you. Don't give up on the foam and thank you for watching.

[@K1ngF1sher]

To those wondering about a hair dryer versus a heat gun: Get a heat gun if at all possible. I've tried both, and the hair dryer is just annoying compared to the heat gun. It takes at least 3 times as long to heat up the foam and usually blows it away before then. Yes, it will technically work, but it's just not the same.

[@BobombGaming]

+GLaDOS Thanks, was wondering about this!

[@CazM]

you can also get low powered bs. high powered heat guns, if you're worried about scorching the foam but don't want to waste time with the slow hairdryer. i have a high power from home depot and a lower power, slightly lower heat one for $12 from Radio Shack.

[@SoSaysSomebody]

You know what would be super helpful, Mr. Evil? A list of all the supplies we need to print out and take shopping or check off. Thanks. Rad work, mad skills!

[@EvilTedSmith]

Thank you MediaMama. I have to thank you for your support. Because with out you these video would not have existed. Love

[@SoSaysSomebody]

Insert adorable emoticon that I'd never use.

[@birdholly]

Awesome video Ted!! Can't wait for more!

[@EvilTedSmith]

Thank you Holly!

[@GeezusQwaist]

HI Ted! love the video! also love the little handymans tinkerknowledge you share! keep up the awesome work!

[@kylerichmond4806]

I am involved in a Star Wars Unofficial Live Action group and this is exactly the kind of tutorials that will help us take our costumes to the next level. Subscribed!

[@EvilTedSmith]

+Kyle Richmond Thank you!

[@kylerichmond4806]

+Evil Ted Smith Do you have any tips for adding visors? I am pretty sure I am good with the rest of the concept for a covering the face but I am a little concerned on how to attach a visor and making it look good.

[@erikaterrosa4459]

basically so far the best foam helmet tutorial I have seen- and ive watched A LOT. Anxiously waiting for part 2

[@EvilTedSmith]

Thank you Erika.

[@sanityisnotmything7610]

This was so fantastic! I've been looking for a good tutorial like this.

[@EvilTedSmith]

+sanityisnot my thing Thank you for watching.

[@Bogusindustries4]

Really been looking forward to this! Awesome technique. looks way faster than pepakura.

[@TaoDeInsane]

This is easily the best set of videos I've seen for showing people how to pattern, cut, and finish foam armor. Showed me things I hadn't even thought of that were total need-to-dos.

[@VizD1]

Great tutorial can't wait for part 2!!

[@CharlotteSomething]

Just finished my first helmet. Considering it's my first ever attempt I'm pretty happy with the outcome. Attempt no.2 is next week. Thank you for posting these tutorials, don't think I would've been able to do it with out them. :D

[@DamenVain13]

Very helpful I'm planning a tmnt shredder costume and been trying to figure out a way to do the helmet

[@RageOfAquarius9595]

Definitely sticking around for more!

[@JOkerAkaMRjj]

Very nice tut! Will definitely try! Keep em coming!

[@CurrentlyDisconected]

Dude that was awesome I finally found a decent foam cosplay video that makes complete sense. I am ready to learn Master

[@EvilTedSmith]

***** Thank you.

[@ready2ripple935]

Just found this channel today because of diy prop shop on the man at arms channel and started watching so many of your videos. Love this channel.

[@EvilTedSmith]

Thank you for subscribing.

[@EvilGenius.]

Awesome build man!

[@robertvermillion4477]

This was a great tutorial! Can't wait for the next part, I'm definitely going to try this for a costume i plan to make later this year!

[@texaschicken9944]

What if I dun hav a head cast how do I draft the helmet?

[@Manuel_Z_Kayaks]

The register marks you made on the pattern were the actual size of the head, when you transferred them to 1/2" foam you put them on the outside making your helmet 1/2" smaller than the head. I guess that would be good for a tight fit but if someone has big ears thats going to hurt after a while.

[@bhermoth]

phartattack true, i used this tutorial for my nephews halloween costume..it looked amazing but it hurt his head after a while and felt so bad...learned from my mistakes, now i just make the pieces bigger for a better comfortable fit

[@scottgardener]

I can't thank you enough, between these videos and your panel at All-Con!

[@EvilTedSmith]

Thank you for subscribing.

[@PatrickSturgill]

Great tutorial Evil Ted! Thanks!

[@EvilTedSmith]

Thank you T.L. Sitter for reposting.

[@AS-3D]

would i be able to use a hair dryer etc. instead of a heat gun??

[@TheMediaKnights]

+SPEED DEMON you can depending on how hot your hairdryer gets and how thick your foam is, it'll just take longer since heat guns get way hotter than a hairdryer

[@MoazIkhlas]

Evil Ted Smith Hi Smith! I love your videos they are awesome and I have the same box cutter and I need an X acto blade!!

[@niltonothing743]

Evil Ted Smith what if you want the helmet to be comepletely closed like for a sans head for cosplay

[@sub0sandwich32]

thank you this really helped for my megaman cosplay! +1 sub

[@EvilTedSmith]

Glad to hear that!

[@kesterfae5447]

haha same here dude. Megaman can be tough to put together. Especially the Buster and legs. Haven't figured that out myself yet.

[@sub0sandwich32]

Yeah I made a prototype out of thick paper and then reconstructed it for the legs out of foam. hope that helps some

[@jamesodin1784]

Thanks for taking the time to do these videos

[@JnAStudios]

Push pins!? Frickkin' brilliant!!!

[@melonpigeon6641]

Best video tutorial ever! Love your video. you got a sub!

[@EvilTedSmith]

Thank you.

[@thebigo81]

I've been wanting to make my own cosplay armor for some time now but every video just makes it seem too complicated or hard. Thank you for your easy to follow steps. You just earned yourself my subscription. Keep up the great work!

[@EvilTedSmith]

Dazin Gaming Thank you Dazin.

[@doublexpete]

This is fantastic!! Cant wait to see more!

[@y2d3050]

Keep making these video's man! Like how in depth you are about it!

[@SpookNukem]

2:04 - 2:06 Turn on captions

[@Boulouteifull]

Spook Nukem Amazing!! Thanks man =D

[@VileSelf]

Spook Nukem HAHA! I've been watching vids with captions on lately.. its hilarious!

[@Juff-]

+Spook Nukem You have showed me the way

[@MiGujack3]

Filthy KZbin

[@hottflames9164]

+Scum of internet lol 2:10 is just filthy

[@DaedalusProps]

You, my good sir, are a BOSS.

[@DaedalusProps]

PLEASE make more videos like this. As someone who primarily works with foam, your videos are GOLD.

[@EvilTedSmith]

Thank you. More to come.

[@DaedalusProps]

Looking forward to it

[@DaedalusProps]

Evil Ted Smith I've actually been showing more and more people your channel! I find your videos to be more educational than my own.

[@EvilTedSmith]

Thank you Demon, I like your videos as well. You do good clean work.

[@MargaritaGakis]

I'm making a helmet for my nephew and this video was soooooo helpful. Thank you for doing this step by step! Your instructions are clear and I can see exactly what you're doing. Thanks for all the time you put into this!

[@ryantrioxin]

Super informative. I've seen your work for awhile now and I'm so glad you put this up. Thank you!

[@spartan159]

Wow, these are so helpful! It's rare to find a step-by-step all the way from free foam-forming till finish! Never heard about using concrete adhesive to keep the foam together...I wonder if for a beginner if this is better than glue gunning?

[@EvilTedSmith]

Spartan159 Yes! Way better than hot glue!

[@ashleybuchanan1603]

Hey there, I am about to start working on a helmet from the new version of Thor (female that just came out). Do you have any recommendations for the face area of the helmet. It seems very thin around the bridge of the nose and eyes.

[@bransonhauntedhills]

That was great. You are really good with tutorials.

[@Lorn058]

This is very informative and spot on! Thankyou sir!

[@c3diy]

Hello! how would i have to draw and cut the patter for a full masked helmet? since it needs to not sit flush on the face but be more of an hybrid between mask and helmet

[@klisterable]

I'm wondering that too

[@cjc1216]

yes i was wondering the exact same thing everyone should thumbs this up so he sees

[@jawjarrose]

cedricfilm if you're thinking like Dr fate I'd ad card to the front of the head you're making the pattern on so that you can cut your shapes to that 😊😊 hope that helps

[@billghli]

cedricfilm if you mean a bit like deathstroke then I'd say watch the tutorial at the top for making his mask because that guy uses a very clever technique I'd never have thought of :)

[@dubbingcollapse9966]

cedricfilm I never marked the cheek-bones and just took it together as a full helmet. I hope that was what you mean.

[@insertname8811]

Dang I would buy the helm as it is in this vid :3

[@dmagginnis]

P.S. I played the rest of the tutorial parts to keep me company while I was gluing with hot glue. Don't have the money for proper fabrication equipment. Although tedious for a person without proper tools n such, still very enjoyable as usual. My motivation is the final product.

[@lcRadec]

Ted, you are the man. Thank you so much for these videos. I'll definitely be passing them around to friends

[@briancook9915]

Thank you for the video! I'm having problems with size though. I've used the foam head and wrapped it in paper mache to be the same size as my head. However, when I transfer the templates to foam, and put it all together, the helmets are always too small. I'm guessing because my template is the size of my head, transfer to what is the outside of the helmet, thus making the outside of the helmet the size of my head. Any words of advice?

[@hypnotikz6227]

make your head sculpt slightly bigger like a couple mm

[@NoxusBolgar]

Really informative, and the hash marks are pure genius. Do you think it's worth trimming the edges underneath to make matching up hash marks easier? or just muscle through and trust in the contact cement?

[@EvilTedSmith]

I find it easier to do them on top. Not only our you lining up your hash marks, you're making sure that the foam stays flush has you press it together.

[@beachcomberbob3496]

If you have trouble drawing a straight line over the curve of the head, try using the spring steel spine out of a windshield wiper blade. If it's a thin one, you can even duct-tape one end down and bend it all the way over. Makes a handy straight edge!

[@christinar7267]

just wanted to say i am very impressed by your tutorials, professional and informative. i look forward to your future shared projects!

[@Silverback67]

This was amazing, thanks so much! I have never tried creating anything like this, but I am gathering up materials for my first try! My biggest hurdle right now is not having a correct sized mannequin head to create the template from. Is there an easy way to get a "fake head" that is close to the correct size so I can create my templates on it?

[@Silverback67]

Lyle Schulz Looking at some of the comments and I see in the list under your video that you can buy a mannequin "bust" for $65.00. I may do that, if there's no better/cheaper option...

[@joshuasales3889]

Can I use a hair blower instead of a heat gun ?

[@adamkadmon777]

Looking forward to more.

[@Lckydez]

Outstanding, you make the instructions so simple. My hats off to you sir.

[@larrybaker7824]

Hey Ted, wondering if you could answer a question? On the generic chest armor chest piece you sell, to enlarge that piece, from the spots it is marked to enlarge from, would I just add a straight piece to the edges or do i need to follow the angle of the pattern? Thanks!

[@EvilTedSmith]

Yes, you could just add a straight piece of foam as well.

[@larrybaker7824]

Thank you for the reply, the templates, and the instructional videos! Saved a lot of time for me in a crunch. Thanks again!

[@jasonharvey3154]

can you please do a tutorial on how to make genji's mask and or armor?

[@Searching4Solace]

Lol we're all having the same idea

[@jasonharvey3154]

+Lunar Bro I know right? And main reason is I cant find any pictures that show his helmet from the front the sides, back and top anywhere and this guy has the talent for it

[@Searching4Solace]

Blizzard released models of all the characters, you just have to use your imagination for the angles not provided

[@jasonharvey3154]

+Lunar Bro yeah, it makes it more complicated and than it feels more fulfilling

[@ninja8077]

Hey Go to playoverwatch.com under the media tab. Blizzard has reference kits for all the characters. I think they had both 2d art and 3d cosplay in mind. I'm going to be trying for reinhardt. :D

[@JayPerkinson]

Great first video!!

[@chrispottle7143]

Wow...just what I wanted to see! Thanks Ted...no skimping on technique or fast-forwarding through stuff. Been trying to find out about this sort of thing for years. Big subscribe and 'like' from me! Thanks again

[@EvilTedSmith]

+Chris Pottle Thank you for subscribing.

[@Joeyblondewolf2]

Awesome Vid! I am also a Big Anime cosplay Nerd on my Channel lol

[@thepwee]

Im call BS on the 40 thumbs down..I saw this guy at the 2015 Comikaze.. F--In amazing stuff..beautifull work....thank you for the videos and talking to me at comikaze....

[@EvilTedSmith]

+thepwee Thank you for your kind words, and for subscribing.

[@Manuelsergio1966]

Thanks a lot Ted, very illustrative!

[@truLu87]

This is really cool, and very helpful. Thank you.

[@RamblingGreek]

This looks SO much easier than Pepakura and much cheaper than 3D printing.

[@EvilTedSmith]

Yes, it is. I want to teach people to build there own stuff.

[@RamblingGreek]

I think you've succeeded on that, I bought some foam floor mats today and will continue my project tomorrow, so a big THANKS to you!

[@iceman6589]

Evil Ted Smith please, i watching all your movies i learn by myself since five years you're so amazing artist

[@RamblingGreek]

Evil Ted Smith I live in Europe, what are the alternatives to Barge? What should I ask for when I get to the Supplies store?

[@hashtastic3537]

Weldwood contact cement.

[@purplepineapple7893]

Mr. Ted. I was wondering. ... lol Is the transfer paper step necessary? Because the thought came to mind during cutting my butcher paper that I could've just skipped that part? Lol 3:00am here. Crashed.

[@EvilTedSmith]

Prencess Fishey I transfer them to paper to clean them up and for easy storage. So that I could use them again another day.

[@Tnilge]

Evil Ted Smith I may be a bit late to reply but does the type of paper used in the transfer need to be specific, or can I just use printer paper if my pieces are small enough?

[@ajax54]

Peanut Any type of paper will work

[@allouttabubblegum5622]

The vidtorial that started me down the fantastic road of working with EVA foam and Cosplay costume making. Thank you for sharing what you love to do, so we can too. Sir Evil Ted you rock!

[@KIThornton1992]

Awesome, thanks! You are very easy to watch and follow.

[@agentdarkbooty6995]

If only I had a cast of my head

[@sharonmccormick8840]

19:26 hahah looks like Magnetos helmet from xmen hahahahahhahahah

[@Emmabellish]

This is a great video! Can't wait to see more from you!

[@clyrus]

I've seen videos like this one before and they have been more fun than cool, this was was awesome.

[@aizony7]

ITS LIKE BARGE SPONSORED YOU OR SOMETHING

[@EvilTedSmith]

Aizon Bellam Ha ha… I wish!

[@ThereminElectro]

Barge is just great, especially their lacquer, makes cleaning latex masks of skin tags super easy

[@nigelburns727]

This is the exact thing I was looking for! Great work!

[@funvash]

so glad i found this, and GREAT tutorial!! i'm headed to home depot tomorrow morning!!

[@nakutube]

Thanks for this! One of the best tutorials I've seen: informative, well-filmed, easy to follow. Thanks for taking the time. Much appreciated!

[@warriornpo1291]

This really helped me in making some helmets. Thanks man!

[@firsttbone]

Nice Ted. Thanks for putting this together. Can't wait to try my hand at it:)

[@emilwestgaardhenriksen1715]

Thank heaven får the kids section in the art store and their rubber rulers 😂😂😂 that sucker just forms itself to the contour of the mannequin and makes your life so much easier drawing the center line of the head 😂😂😂

[@ZapZapMimi]

I am in love with you and your foam masterpiece.

[@talginlvl90]

thank you this helped me so much with making my helmet pattern, i never thought to pattern it like that.

[@clintandren4685]

Thank you, Ive been thinking of making a helmet and your video really helped. Good job Ted!!!!

[@dirtyrotten666]

great video...its the missing link to my 1st build. cant wait for the next videos.

[@OneClickAlternative]

Where has your tutorials been all my life! You make this look so easy!

[@EvilTedSmith]

It will get easier in time.

[@rookieroo24]

Great video, and excellent tips! I've been using Pepakura for a while now, but this has really given me insight towards freehanding my own patterns! Thank you, Ted!

[@Jbtorresmedina]

Excellent Work, Ed! Feeling Inspired!

[@EvilTedSmith]

Jose B Torres Medina Thank you for watching!

[@caseyhoran7116]

Looks like a lot of work, but I'm sure it's worth it. I've always been interested in working on costumes, though I've never worked on Foam before. It's so thrilling to see something being made

[@xpepness]

I remember seeing you on a DIY Crabcats video, so glad you're making videos now! Excited to see what I can learn from a foam prop making expert~

[@MattMcRB]

Saw your work on Tested, this is my new favorite channel, love your work!

[@EvilTedSmith]

Thank you for subscribing!

[@JACKPICON]

I can't believe how easy and simple it is... good work!

[@AlbertoMartinez765]

WoW I learned so much man! Thank you

[@alyssazappe]

You're the best! :D now I'm even more excited to make my costume!

[@Trashgriffin]

wow awesome mate, thank you a load for this tutorial. you explain your process very well!

[@rutherdei800]

I love your videos! Extremely helpful, Evil Ted Smith!

[@EvilTedSmith]

ruth Erdei Thank you for watching and subscribing.

[@thecoolkidsclub1436]

Evil Ted Smith can i seal foam with modge podge

[@WYSawada]

I've been thinking for weeks on how to make a helmet ,until I found this video! Thank you very much!! This tutorial is very detail !!!

[@jairoguedz4062]

Man, you are great and explains everything in a good way for us to understand. Thanx and congrats for your kind.

[@MyRedStallion]

Great video, thank you. Cant wait for the next part.