Uruk-Hai Berserker Helmet

I had some free time to build something for myself so I decided to make the Uruk-Hai Berserker helmet from The Two Towers. I started by creating a 3D model in Strata3D.



Pepakura is a Japanese program that converts 3D models into paper models. Once converted, you print it, trim out the pieces and glue them together. I printed out the results on Staples cover stock. I find it holds the shape better than paper but it's still easy to cut out and glue.



After cutting out all the parts, I assembled the pieces using white glue.



Detail of the tabs that Pepakura adds to the geometry of the model. While I could have sculpted this helmet in clay, it's much easier to stay symmetrical with a paper model. Also I save the cost of mold rubber.



I built in thickness to the eye holes and around the opening to add rigidity to the model and to make it easier to keep resin on the inside.



The completed helmet. I added bands across all openings to help the model keep its shape. Paper is easy to work with but bends a lot if it’s not properly supported.



Side View. Although I modeled the back plate, once I built it, it was too rough to use on the final piece.



Using Smooth-On SmoothCast 65D in small quantities, I started to build up the thickness of the helmet walls. The resin is slushed around in sections until it hardens.



The resin cures in a few minutes to an opaque white. If you pour too much inside at once, its own heat causes it to solidify in chunks rather than spread out over the inner surface.



I reinforced my spacers with wood sticks to lock the helmet into the proper shape before the plastic walls got too thick.



After I built up enough thickness with plastic, I used Bondo to smooth out the exterior.



Using the paper model as a guide, I cut the back plate from 1/8" styrene and heat formed it to the helmet.



I cut the base of the back plate from 1/8" styrene and glued it to the back plate.



I added a curve to the seam with Bondo and then epoxied the back plate to helmet.



I made rivets by pressing an acrylic dome into clay and poured 65D into the holes.



Instant rivets!



All the rivets glued on.



With all the major construction done, I applied a base coat of Hammered Silver.



I dry brushed rust to the rivets and to damaged sections of the helmet.



Next came a wash of black to knock down the shine and bring out the detail of Orcish craftsmanship.



The final touch is a gentle application of the White Hand of Saruman.



Using some scraps of leather, I made the chin strap and hot glued it to the inside.



I cut a buckle from a scrap of steel.



I gave the metal a rough hammered finish with a hammer. Dur.



I cut some fire and bent it to form the tongue.



Once the buckle was in place, I glued the strap around it. To finish the look, I gave it a quick stitch with sinew.



I punched holes in the other strap and gave the end a rough cut with dull scissors.



The final helmet ready for war!



Side view.



Back view

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Detail of the side.



The wash really brings out the scratches.



"Looks like meat's back on the menu, boys!"



Although there's no room for padding, the helmet is snugly comfortable and offers a good range of vision. At least to anything in front of you. I especially appreciate the beard room!



PDF of the Pepakura model