Ever have a project you thought would be a breeze, and then it ends up taking 8-10 months?
Well, it turns out, the Knights Who Say Ni really DID demand a sacrifice: all our time and patience.
We're on the home stretch now, though, so let's get to it!
Oops. Sorry, guys. I'll try not to say that word again.
Without further ado, our completed helmet:
We've made seven total, though only 6 are show-worthy. They're made entirely of EVA and thin craft foam, and the horns attach with magnets:
This makes storage & transport much, MUCH easier.
I lost count of how many tries it took us to get the helmet shape right, but here's just some of the reject pile:
Once we nailed the shape the rest was relatively easy, though, so if you want to make your own, rest assured we've done the hardest part for you. (And if you're so overwhelmed with gratitude you want to help feed our cats and/or shop through our Amazon affiliate link, then hey, I won't stop you.)
The helmet is just four pieces of EVA foam (which you can buy in rolls at Harbour Freight, Walmart, and/or many hardware stores), while the horns and trim are the thinner "fun foam" from the craft store. You'll also need contact cement to assemble everything.
This will not be a full step-by-step tutorial - there is too much. Instead I'm going to give you our templates and some quick pointers and explanations. If you get stuck feel free to ask questions in the comments, though!
First, the templates John very sweetly labeled and arranged so you can print them on standard paper at home: