How to Make a Knight Helmet (free template file)
What little one doesn’t like to play dress up? This how to make a knight helmet tutorial will show you how easily you can make Knight Helmet for your brave squire. 
With just a few simple materials and the free template he’ll be fighting dragons in no time.
I confess that I’ve had this project sitting in the back of my craft closet fora a few weeks. Between all the other items I wanted to get done, morning sickness (more on that in a minute) and the general chaos t comes with family I didn’t have time to take pictures of the helmet and shield. Every Once in a while my son would point to them and ask if he could play with them and I would put him off, explaining that we needed to take pictures first.
Finally the day arrived where I wasn’t feeling like death warmed over and we ventured out to take some pictures. 
Needless to say my little one was thrilled that he finally got to play with the knight helmet and shield and proceeded to where them on and off through out the rest of the day. 
No matter how tech advanced we get there is something alluring about playing knights! So today I’m very happy to share this tutorial with a free templates so you can make a knight helmet and shield for you little one.
And yes I’m pregnant with baby #4 that’s due at the end of April 2018. So I’m in the middle of morning sickness and have been not feeling my best.
For this project you will need:
Cricut Maker or Cricut Explore Air 2*
2 large gray sheets of craft foam ( 12″ by 19″)
Access to Cricut Design Space
Glue Gun and Glue Sticks
Fleece Fun’s FREE SVG File (available at the end of the post)
Mod Podge (optional)
Silver spray paint (optional)
Black paint (optional)
Foam pain brush (optional)
Small paint Brush (optional)
*If you don’t have a Cricut machine you can print out the template, trace it onto the foam and cut it out with and exact o knife. BUT the machine is much easier and faster.
How to make a Knight Helmet Tutorial:
Step 1 – Upload the file to Design Space
Download the free SVG file and then upload it to Design Space. Make sure that all the images are attached to each other so the Cricut will cut out the helmet and the finishing pieces on one sheet.
You will need to cut out the knight helmet one regular and then a second time MIRRORED.
This is because the rollers can leave marks in the foam and if you don’t plan on paining your helmet you won’t want lines running across it. Continue the how to make knight helmet tutorial.
Step 2 – Begin to Assemble the Knight Helmet
Once you have all your items cut out pop them out of the foam and off the mat. Take the two mirrored sides of the helmet, with the side with the roller lines facing down, begin to hot glue the helmet together, starting at the front bottom.
Only glue an inch or two at a time, joining the foam together right at the edges.
There is no over lap on the seam. As you begin to work with the curve of the knight helmet, go slow and give the glue time to harden a little before adding more to help it hold it’s 3D shape.
Don’t worry if the seam has clumps of glue, or looks a little uneven, we’ll cover that up later.
Once you’re glued the front to the top time, glue the back, beginning at the bottom and working your way to the top. Again, take your time and go slow. Continue the how to make knight helmet tutorial.
Step 3 – Assemble the Sides
Now that you have the back and front of the knight helmet glued together, it’s time to glue the side and make it fully 3D.
Starting on one side, begin to glue, making sure the knight helmet maintains it’s curved top.
Once you have on side glued, glue the other side, trying your best to get the seam to line up at the top.
Again it’s ok if it’s not perfect and there’s a little gap or hole at the top of the knight helmet, we’ll cover it up in a minute. Continue the how to make knight helmet tutorial.
Step 4 – Finishing the Seams to the Knight Helmet
Remember all those extra bits you cut out with the helmet? Now it’s time to use them!
Take one of the long strips and glue it to the top of the seam, covering it up.
Repeat with the front and back sides.
Finish off the ends of the seams or cover gaps with a circle. Continue the how to make knight helmet tutorial.
Step 5 – Paint the Knight Helmet
This step is COMPLETELY optional. The knight helmet looks pretty good if you just leave it as gray craft foam. But if you want to take it to the next level here’s how to do it.
Using a foam brush cover your helmet with matte Mod Podge and allow to dry completely.
Repeat with a second coat and allow to dry.
Spray pain with silver spray paint (or desired color) and dry brush with some black pain to give it a more worn look. Allow to dry. Then cover in a final coat of Mod Podge to seal the paint on ( if you don’t seal it on, the pain will rub off! You’ve completed the How to make a Knight Helmet tutorial!
Bonus! – How to make a Shield
I didn’t want to include a whole other tutorial for this (it’s really simple) so I’ve included the shield SVG for you too!
Simply cut out the shield front, Then cut out the front layer and back handles. Glue the front to the front and the handles to the back. You can paint the sheild following the same instructions for how to paint the helmet. Enjoy!
Download the free patterns!
More Costume Tutorials:
- All of Fleece Fun’s Costume Tutorials
- How to Make a Crown (Free SVG)
- DIY Tiara with free SVG Pattern
- Branch Trolls Costume
- Harry Potter Wizard Robe
- Easy Donut Costume
- No Sew Knight Costume
- Fast Hooded Cape
- DIY Jedi Costume
- Inspired by Disney’s Aladdin Vest