Before I started making the helmet, I looked up some images on Google of it to get an idea. I first looked at the helmet from the game itself and then I looked at fan made (cosplay) versions of the helmet (below).
As you can see, the horns and shape of the helmet is slightly different. I looked up many other helmets made by fans and they all seem to be different in many ways (shape, colour, size, material, etc...). These Youtube videos helped me a lot while doing research, so thanks to them!
I also used the images from this website for reference. I found it very usefull!
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STEP #1
So, here is step one. I cut out long strips from a cardboard box to make the skeleton of the helmet. I then measured the strips around my head and then stapled them together.
STEP #2
I then got an A4 sheet and marked where my eyes and mouth are on the paper (like in the 2nd video above). After masking the eyes, I drew the shape of the mask and cut it out (no template used).
STEP #3
I used the cut-out as a template. I got an old foam camping mat and cut it out using the template. I was limited with the camping mat so I had to cut it up in many parts. After cutting all the parts, I stuck them onto the cardboard frame using hot glue. Do not stick the face piece on yet!
STEP #4
Now that the foam is stuck on in shape, it's time to apply about 4 layers or paper mache (weaker parts may need more). To make the glue I used baking flower and hot water. The glue must be stirred well, smooth and sticky. Rip/cut up long and short strips of newspaper to stick on the foam. You can use your hands or/and a paintbrush to apply the glue and paper.
STEP #5
To make the horns I took many pages of newspaper and then squeezed them together. Do not twist the newspaper. Use jute string to hold the horns together.
STEP #6
To fix the horns to the helmet you can use the same home made glue and jute string. It will be easier to cut the horns slightly diagonal so it fits to the helmet.
STEP #7
After the horns are on, apply more layers of paper mache until the string around the helmet is unnoticeable. Then hot glue the face piece and other foam parts where necessary.
The next few steps are alternative and are more advanced. If you want you can start painting the helmet strait after step 7. I used spray paint for the helmet and oil paint for the horns. If you are planning to paint on paper mache and foam, you can use spray paint and/or acrylic paint (oil takes long to dry).
STEP #8
I then applied 1 layer of plaster to make it smooth and give it more shape. I also carved the horns to make them look more realistic. If you want you can cover the face piece in plaster but I didn't see any point.
STEP #9
After the plaster is smooth and in shape, I coated the helmet with fibreglass to make it strong(fibreglass will also help make it look more real after the spray paint is on). Smooth the fibreglass with sandpaper and rough and smooth file. Any holes in the fibreglass can be filled with a scratch filler (I used this one). Don't forget to smooth!
STEP #10
After the fibreglass is smooth its time to paint! I used spray paint for the helmet and oil paint for the horns (I was told oil works better on fibreglass and spray paint). Don't forget to use a primer before the spray paint!
The helmet ways roughly around 2kg. It ways this much because of the amount of plaster put into it. If the inside of the helmet is too hard, you can hot glue some more foam to make it softer. The studs on the front are metal board pins that are hot glued on.
This is not my first time making a prop but it is my first time using plaster and fibreglass. I definitely had fun making this Skyrim helmet although most of it was trial and error.
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