How To Make A Foam Deep Sea Diver’s Helmet. DIY Halloween Costume

How To Make A Foam Deep Sea Diver’s Helmet. DIY Halloween Costume

Do you ever wanna just find a quiet space?
Away from all of life’s stresses? Well, there’s one place that’s always peaceful.
Under the sea. And we all know the best way to visit under
the sea is with your own diver’s helmet. Ahh, the serenity. Hi, my name is Chris and I like to make things. Today we’re gonna make a diving helmet.
The first step is to print out the pattern. Make sure your printer is set to print at
actual size and then make yourself comfortable while the printer does its thing. Once the pattern pieces are printed, you can get off your butt and start taping them together.
Overlap the pages and line up the registration marks. I like to do this on a window so I
can see clearly through the two sheets of paper. Now you can take your pattern and start
cutting it out, cutting just on the outside of the black line. Go downstairs and grab
a big sheet of foam and start tracing your pattern pieces. Remembering to mark and label
all the alignment points. Wherever two of the same piece are required, make sure you
flip the pattern piece over before tracing the second one. I like to designate the flipped
over ones with an “A” after the number so I remember which are which. Once everything
is traced, grab your ocean-themed cutting surface and start cutting.
Once your pieces are all cut out, grab your blowdryer. You can start forming sheets
1, 2, and 3 by heating them up and shaping them over your knee.
Now it’s time to get out your glue gun and start gluing. I just bought myself a super
swanky silicone baking mat. These are amazing because the glue just peels right off. Start
by gluing the V-shaped cutout on piece number one. Press the two sides together while holding
it down against the silicone baking mat. This should leave you with a fairly smooth seam.
Now glue the cutout on piece number two. On longer seams I like to glue about five to
eight centimetres at a time, hold them until the glue dries, and then go on to the next
five to eight centimetres. Glue piece number three to piece number one, using marks numbers
ten and eleven to line it up. Then piece two gets glued onto pieces one and three, lining
up numbers 6, 7, 8 and 9. Glue piece two to piece one, lining up mark 4, and that gives
you half of the main helmet body. And I bet you know what I’m gonna say next – make the
other half and glue the two together. Now grab pieces 4 and 4A and glue the ends together
to make a nice ring, which will be attached to the main helmet body by lining up the front
and back seams. Glue the front and back first and then glue the sides, trying to keep everything
equal. Make another ring out of piece five by gluing the ends and glue the flat side
of that onto piece six. Make sure to line up the marks on the widest part of piece five
with the centre of the tabs on piece six. Now you can glue your new face plate over
that big hole in the middle of your helmet. And again, to make sure it’s all lined up,
glue a little at the top, a little at the bottom, a little at one side, a little at
the other side and then fill in anywhere that you haven’t glued yet. You might find there’s
a little extra foam on the side edges, which you can trim off if they bug you. If it doesn’t
bug you, you’ve just saved five minutes. Alright, now you can glue piece nine on the side holes,
which will be covered with a super funky, fun grid thingo. Just match the slots up with
the other slots with a bit of glue in there and you’ve got it. Make a ring out of piece
seven and glue it on to piece eight, this time lining up the narrowest part of piece
seven with the alignment marks on piece eight. And you can glue that top window to the main
helmet body now. Angle all the corners of piece 16 with your knife and then glue
the grid in place. Glue two of piece 12 together and glue it onto the side of the face plate.
Now we can bend down that tab and glue it so it looks a little bit like a hinge. On
goes the front faceplate grill. Now, make a sandwich of three piece 15s, which will
get glued below the larger tab on the faceplate. Grab your blowdryer and use it to heat and
curve piece 11, so it looks a bit like a bib. Line the tabs up of piece 11 with the front
and back centreline of the helmet and glue them into place. You want to glue it so piece
11 overlaps piece 4 at the front and back by about a centimetre. Now glue the sides
and then the rest of the way around. The extra overlap you left at the front and back helps
the breastplate keep its form once it’s glued down, like so. It’s feeling awesome, but it’s not quite done. Cut a strip of foam 92 cm long by 3 cm wide
and use it to cover up the seam around your helmet. Trim off any extra foam with your
knife. Now cut another piece of foam 90 cm long by 1 cm wide and glue it vertically down
the centre of the strip you just glued on. As we seem to be in the strip cutting mood,
let’s cut another one 150 cm long by 2.7 cm wide and this one will run around the outside
of the breastplate. Oops, I almost forgot pieces 13 and 14. I don’t know what they’re
supposed to be, but hey, they look cool. Make a mark at the centre front and back of the
rim around piece 11. Then make a mark every 9 cm until you’ve reached the top of the shoulder.
Now grab a nut and glue it on top of each mark. I’m also filling the centres with a
puddle of glue, just so they stay on that little bit better. And a wing nut on the face
plate finishes it off. Now paint it black and go play some foosball. Once you’ve let your son beat you in a game of foosball, it’s time to get out your metallic
paints. Wearing a rubber glove, apply a small amount to your finger and then lightly apply
it to the painted surface of the helmet. To get a contrasting colour for the portholes,
I used DecoArt Metallic Lustre. The colour I used was Gold Rush but I mixed in a little
bit of the bronze Liquitex acrylic paint as well.
And once that’s done, you’re done. Thanks for watching and if you want to make
your own diver’s mask, now you can. Boom. I think this is probably one of the best projects
I’ve ever made. I’m super impressed with how it turned out and if I had some reason to
wear one around the house, I would. In fact, I have. If you want to get the pattern, there’s a link right there. Thanks for watching. Bye-bye. I need a bunch of rocks!
I need rocks in my pants. What if I put this in my pocket? That’s not
gonna fit in your pocket! Hey your thing is going away!
I think that worked really well.

100 Replies to “How To Make A Foam Deep Sea Diver’s Helmet. DIY Halloween Costume”

  1. I love all your videos and already bought several patterns you supply (included this terrific helmet) 🙂 May I ask you to think about making a steampunk gramophone with its beautiful horn… that would be awesome !!! Let me know 🙂 greetings from France 🙂

  2. Just finished this. Thanks for the pattern. For a first attempt working with foam, I could have done worse. Would like to send you some pics. What's the best way to get them to you?

  3. just got the patterns, planning to build this with a few modifications namely some exhaust vents concealing fans, spooky looking window tinting (only after making sure a fan can provide enough air) and trying to figure out a simple way to harden the helmet with fiberglass and twist on/off the actual helmet from the collar for a costume im planning… one question, where can I get a roll of EVA foam that size, preferably from a retail outlet found in the USA?

  4. This is a good video, and I'm not dissing it or the creator, but still I'm disappointed that the helmet is just an imitation nonetheless.

  5. I'm giving this a go for a photoshoot we have on Sunday… Complete newbie here but your instructions look pretty thorough and I'm stubborn as hell. I'll send you the pics if it turns out well!

  6. Thanks for the excellent video! I ordered the pattern and made several helmets! The step-by-step instructions were fantastic

  7. you could have cleaner unions if you glue them upside up, don't be afraid trust me! this is awesome!
    you sir have earned my subscription!

  8. im kind of missing the hose connectors tho. but Im guessing you could find some suitable piping from your hardware store and glue on for a quick solution to that.

  9. Though I like most of your videos, you should do some things a bit more correctly. Registration marks are there to be used. You show gluing pieces together without using them and the alignment is off. Just do it right if you are showing people the right way of doing these things.

  10. Wow, that is awesome, i made my own version of the top hat inspired by yours truly and now I have to make this 🙂

  11. Hi Chris, this is awesome. I am almost finished with the helmet. I bought your pattern and it works fantastic. Even a bloody beginner as me can get it done. I use the helmet for our Rock-Show Stage performance. We are Covernaut a Rock cover band who supposed to be a "steampunk-look" expedition team with their Ship Covernaut on the seven Seas. So your Helmet was exactly what I was looking for to complete our appearance. Thanx a lot!

  12. Joints can also be done with contact cement, which is more work, but I trust it more than hot glue for sturdiness. Oh! Nice pattern and workmanship there!

  13. Does anyone know how much of the foam is needed? I am thinking about making it(for Big Sister from Bioshock cosplay) but I need to estimate how much it would cost me…

  14. Also make the nut that sits just in front of the left shoulder longer than the others. This is called the bastard nut and it's where the air line attaches on the real deal.

  15. The diving helmet is amazing! Thanks a lot for the great video and instructions. I got a ton of compliments, 90% should go to you 🙂

  16. Do you have any advice on how to clean up the messy glue seams before I paint it? Sandpaper perhaps?

  17. do. u have a link for a space helmet at all please ?if so please share

  18. Awesome design! I have worked a bit with cardboard but after seeing what you did with foam, I'm giving the diving helmet a try! What did you use for the rounded screw heads on the front face plate?

  19. I think your videos are really cool. My brothers and I enjoy watching them. You should make some Lord of the Rings chest plates, helmets, swords, shields, etc.

  20. I just completed this build! I added a few "details" but this was an awesome project! I highly recommend it! Thank you.

  21. how did it not get wrecked when he went under water? unless it was fake. love your videos  btw get a heat gun. they are not that expensive

  22. This IS most impressive!!! I've never played with foam like this, and I'm amazed at what you've done with it (in this and other videos)! I see an exploration into the world of craft foam, hot glue/contact cement, and acrylic paints in my future – and all because of your beautiful inspiration! This is art!

  23. Where do you source the thinner foam for the band around the bib? I've found some sheets on but they are only 50cm long

  24. Making this- can you share where you got the foam. Or how to find it/what to ask for/google…..??? PLeeeeaaaaaassssse:)))

  25. Is it possible to buy the pattern as a unified file since I can go to a print shop and ask them to print it in one single sheet instead of multiple A4 pages?

  26. Hey everyone, my preferred paints and supplies change over time. You can check out my current favourites on my Amazon page (affiliate link)

  27. THIS IS AMAZING!!!!!!! Love this! I'm making a Steampunk camper and going to make this into a light fixture! THANK YOU!!! Please come up with more Steampunk ideas!

  28. What thickness foam should I order for this project and sq. ft. needed? I see on Amazon it comes in various stiffness too… do you know what stiffness level to buy also? Wanted to know ahead of time so when I order my pattern I have my foam already.

  29. Hello! I was considering making this out of cardboard and paper machė. Have you ever thought of working in different materials than foam?

  30. I made this helmet. and I love it. I wear it on stage.

    check out Scotty Dub & The Jellyfish on all social media.

    thank you thank you thank you.

  31. What thickness foam did you use for this I want to make it for my grandad who used to dive using one of these helmets

  32. They make bigger silicone mats. I saw one that’s 24×60 and it’s gridded. This a great project for anyone doing a diver for Halloween or underwater theme for a party and have a dummy or skeleton in it but be sure to make the entire outfit.

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