Cheap Agen Port Project

[btswanfury]

So, I decided to try my hand at making an Agen-Port style "war hat" helmet. For this project, I am using a 1950s-model US civil defense helmet as a base. Yes, I know, it's not perfect. But for $15, I figure it's a good first-time project, which can always be consigned to the loaner pile when something better comes along. The way I see it, I can have something custom-made (expensive), or satisfy myself with what is available from Deepeeka and Windlass steel crafts. Since I don't have the money for a $500+ helmet, and the Deepeeka/Windlass helmets are not necessarily more authentic than what I am doing (being made using modern processes and modern metals, etc.), I decided I would simply make my own from pre-existing materials. Something that looks right, feels right, and is custom made, that I can take pride in. Plus it will be unique, as no one else I know (in my area, anyway) has one of these. So, enjoy. I will keep you all updated at things progress.

Also note: this can (and has) been used to make Roman-style helmets as well. Just a thought.


An original, 1st century BCE, Rhine area.


Another original for inspiration. Also 1st century BCE.


The original helmet with paint job. 1950s era, steel construction, with web liner. I got 2 for $35 on Ebay plus shipping.


First things first. I cut out the liner with scissors, and then used a rotary tool and cutter bit to remove the washers and rivets. The remainders of the rivets were pounded out with a hammer and pulled out with the pliers.


Next, I cut the bales off with a diamond wheel on a rotary tool. The diamond wheel might have been excessive, but since I have neighbors, I wanted to get it done as quickly as possible to not disturb their Sunday!


Another view of the inside of the helmet, minus bales and liner.


Next: using a very toxic cleaner to strip off the old paint. I'm not sure if the paint was very old and so baked on, but I was not impressed with the stripper. It took a lot of sanding with a sanding sponge and wire brush to get the paint off.


Outside mostly done. Still need to fill or cover those rivet holes.


Completely stripped, and now oiled.


Another view. Getting the paint out of the inside of the bowl was tricky.

Next time: making cheek pieces, and brazing/soldering/welding on a brow ridge. Stay tuned!

[Robert]

By the looks of it, you could USE those rivitholes to fasten the extra rim, which is very characteristic. Even if you do not use them, they look to be covered up by that projection.

[Primvs Pavlvs]

I made a Collusion type helmet from one of these helmets, its actually the helmet I am using for my kit these days. I will try to add a photo later today. I used blind rivets to fill the holes on mine.