instructables

DIY Hawk Helmet

by JasonP4

Here's a killer bird helmet for you fans of the feathered heros!

You can either download the les to laser cut or print, trace and cut your own cardboard or other ~1/4'' material.

Note: Use gloves to avoid paper-cuts from laser cut cardboard (and hot glue). Sand the edges a bit for less risk of injury.

M a t e ria ls ne e de d:

PDF le linked above. 18" x24" (use acrobat to print it to multiple sheets if you are using a smaller
printer)
Three 18" x 24" cardboard sheets (if using the les linked above) OR cut the pieces from a case of
beer for a super silly birdman.
GLOVES! Laser cut edges are sharp! Use gloves especially if working the the laser cut kits and hot
glue
Sandpaper
Hot glue
Wood Glue
Masking tape or packing tape
Metal straightedge ruler
Scissors or a xacto knife
If you want to do these projects with kids, or just don't want to work with a sharp
blade, check out Make-do Safe Saw: https://www.make.do/products/safe-saw-005 and
other similar tools.

Rolling pin or cylinder for shaping curves

DIY Hawk Helmet: Page 1

 Download
https://www.instructables.com/ORIG/F42/BYUB/IFF8BL72/F42BYUBIFF8BL72.pdf
…

Download
https://www.instructables.com/ORIG/F5Z/W67T/IFF8BL7E/F5ZW67TIFF8BL7E.pdf
…

Download
https://www.instructables.com/ORIG/FDT/4H6U/IFF8BL7F/FDT4H6UIFF8BL7F.pdf
…

Step 1: Some Tips for Folding and Gluing

Let's start with a few tips for gluing as you start on
the helmet's main dome. Curl each of the prongs of
the dome around a rolling pin to loosen them up and
begin to help them get into shape. As you can see in
the rst image, I used a paint roller for this build. I
rolled all of the prongs along their length, and then
rolled the sides of the mask inwards (perpendicular to
the previous rolls). See the second image for the
result.
When gluing, apply the glue into the corrugated
edges (image 3) and either hold or tape the edges
together as the glue dries/ cools. Gluing into the
corrugated edges is my preference, but it also works
well to hold the edges together and glue along the
back (image 4). In this case, I did both.
Personally, I think wood glue gives the cleanest and
most sturdy nish, but hot glue is faster. Hot glue can
also be more forgiving as you can re-heat and re-glue
if you're unsatis ed with your seam.

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Step 2: Fold and Glue the Helmet's Dome
Use the techniques from the previous step and the
pictures in this step to fold and glue the dome of the
helmet. Start with the two center prongs, go slow and
work from the base of each prong to the end, one at a
time.
Then glue the sides into place as seen in the third
image. They will need to be curved outward, but we'll
force them into place when we attach the wings.
As you can see in the nal image, I use masking tape
to hold the seams together while I work. This helps
the build go a little faster, but don't rush through.
Take your time and let each seam dry/ cool in the
DIY Hawk Helmet: Page 3
right place or you'll end up out of alignment for the
next pieces.
If the folds get confusing, trace the part onto a sheet
of paper and tape it together. This should help you
understand how the part works without wrestling
with thick cardboard or damaging your laser cut
pieces while trying to gure out the folds.
Also, there really is no set order for assembly, so look
over all of the remaining steps and feel free to take
your own path.
Step 3: Assemble the Wings

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This is going to be the toughest part, so let's get it out
of the way. By the end, you're going to be the
cardboard whisperer!
Please make sure you're wearing your gloves,
especially if you're using the laser cut double ply
cardboard from one of my kits. These feathers are
SHARP and the gloves will also help you wrangle hot
glue into place easier.
Start by identifying the six (three for each side) wing
pieces. (images 1-3) Begin folding the wings into
shape by following the rst 5pictures. Identify the
inside and outside of the wings using the photos here
and create folds along the 90 degree edge of each
feather. Use long thin part show in the 6th picture to
guide your folds as well. This thin part forms the front
face of the wings, so it shows you very clearly where
to fold to are the wings out a bit.
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You really don't have to get everything perfect, you
really just need to loosen up the cardboard (as we did
with the roller in the rst step) and mold it into the
general shape. You'll really impose your will upon
these wings when you apply the glue.
Line up the tip of the triangle shape of the front
feather and apply glue to the at surface of the
cardboard (not the corrugated edge as we did before).
It's pretty important to line up the very tips of the
triangles as you glue or these parts will become
increasingly di cult to align. Usually I work from one
side to the other (front to back or left to right) when
gluing, BUT in this case I glued the front feather,
middle feather then second from last feather. These
feathers need to be folded and pressed tightly when
glued so jumping around worked best for me.
DIY Hawk Helmet: Page 6
Step 4: Fold and Attach the Sides to the Dome.

Before we can attach the wings to the dome, we need
these side parts. Notice that they fold along the slits.
The back bit folds 90 degrees around to form a
conical shape. The rst two images show how to fold
and glue these parts, and give you a look at the
outside and inside so you can see how I do it. This part
can get annoying for the wearer, so sometimes I just
cut the folded sides o completely.
Now attach them to the dome by lining up the sides
that match (see image 3).

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Step 5: Attach the Wings to the Dome

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Line up the font/ bottom of the wings with the dome would be exhausting. Once it's in place, re-enforce the
and sides as shown in the rst image. Don't try to glue seam by gluing and taping this seam from the inside.
the entire seam here, as we'll need to do some
shaping as we glue. We're not going to nish attaching the wings just yet.
Instead we'll attach the lower back "tail" of the helmet
Once you've got a good t with the rst edge, push in order to help with alignment when we close
the cardboard into shape from the inside as you glue. everything up.
Hot glue is probably your only option here, as holding
wood glue in this shape long enough for it to dry

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Step 6: Fold and Attach the "tail"

The lower back of the helmet adds a little air that should fold out and under. We'll call this the tail. Fold as seen in
the rst image in this step and the attach it to the lower back end of the dome part (image 2).

Then glue the faces of the three tail feathers to their corresponding feathers on the wings. (image 2).

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Step 7: Finish Attaching the Wings to the Dome

I used a wooden spoon to help create a little depth in
the wings before gluing everything together in this
step. Insert something to wedge the hollow area of
the wings outward and help the wings reach the
dome. This area doesn't need to line up exactly, as you
can really glue the wings onto the dome anywhere
you can get them to line up. Depending on how much
you ared the wings outward, you'll need to do a little
forceful molding as you glue to get everything to
work together. In this build I kept the wings pretty
vertical, so I'm going to have to wrestle with the wings
to get them into place.
I actually prefer to stop at this step. I think this helmet
looks great with the open face mask, but for this
build, lets go ahead and add the facemask.

Step 8: Fold and Assemble the Facemask

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The facemask can be really tough. It is intended to
create a brow that recedes into the eye sockets. This
can be a pain to shape and uncomfortable to wear. So,
build it, see how it ts and trim as you see t. I'll show
you how I trim it to make it more comfortable.
First, fold the beak as shown in image 1 in this step.
Curl the ends around a cylinder to loosen and mold
the sides up a bit.
Don't glue the ends near the tear ducts yet, you'll
need a little wiggle room to get the facemask into
position.
There is a triangle shaped part in the pattern that I've
left out here. It goes underneath the beak. If you
include it, you'll have a tough time getting this
helmet around your nose. BUT you can use it to see
exactly how the beak should be folded.

Curl and shape the brow as seen in image 2, and glue
the two parts together. Start with the square at the
end of the nose. At rst it seems like it doesn't match
up, but fold the little square tab back and glue the
part from the rst image behind the end of the beak.
Likewise there are two curved parts that extend even
further into the eye sockets. Leave these out unless
you do not plan on wearing this helmet.

Step 9: Attach the Facemask and Add the Final Trim

If you line up the brow exactly, the facemask will Pull the nose/beak forward by squeezing the sides of
probably recede into your eye sockets too far to the helmet inwards and glue the beak to the brow
comfortably wear. So, extend the brow out from the (image 3).
helmet a bit when you glue the brow (image 1).
Notice in the nal image in this step that I've trimmed
Glue all the way around the brow and the sides before the corners near the tear ducts to avoid being poked
gluing the nose (image 2). in the eye.

DIY Hawk Helmet: Page 12

DIY Hawk Helmet: Page 13
Step 10: Finish!

Nice work!
That was tough, but you've done it! Your helmet is
ready for paint/ bondo/ wood ller or just take it to
the streets.
Before wearing I recommend attaching some elastic
straps to the long side pieces to help keep the helmet
in place and more comfortable. I also attach elastic
straps or foam behind my head to keep it in place.
In the nal image here, you can see that I've nished
mine with black paint, glitter spray, faux leather and
black feathers.
The helmet from the cover photo was used in an
episode of Hulu's "Deadbeat! Check out the last
photo!

DIY Hawk Helmet: Page 14

Great project! Turned out absolutely stunning. For thoose wondering on printing size: download
files, open in adobe reader, adjust photo to 100% and print on a4 with the portrait setting on. (it will
say 24x21 inch i think, but its only becuse its adjustet for a4). The helmet ts a perfct fit for me 56/57
cm, its about a 0,5cm-1cm gap around the head, so glued some foam in some places and its
actually comfortable to wear too. Any smaller and it would be difficult to get on so i recommend
making it and inch bigger than your head. Made some minor changes, thats the magic with
cardboard. Thanks very much!

Wow, super job! The original document is 18" x 24" because I cut these out on an 18 x 24 laser
cutter. So a program that can slice the file up into smaller chunks may also be helpful.
fiz com eva e biscuit!

GREAT WORK!! I love the feathers and detail!

How much do I need to enlarge the pattern so that it will fit my head?

Awesome, I would totally wear it in public!

"Oh, well, who wants to live forever...? DIIIIIIVEE!"

This was great!

This was great!

I might have to try my hand at this one. Great finishing look!

DIY Hawk Helmet: Page 15

LOL awesome dude

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