Patterns (Click on a thumbnail to get the full-size image)

Instructions:

• Cut the head band from 1-3/4" wide 14 ga. 27-1/4" long.
  Cut the front to rear band 1-1/2" wide 16ga. 19" long.
  Cut the side to side band 1-1/2" wide 16ga. 18" long.
  Cut the nasal from 14 ga.
  Cut the panels from 16ga.
  Cut 4 inside strips from 1-3/8" wide 16ga. 6" long.
  
• Dish, shape and roll the head band; rivet or weld it together.
  Dish and shape the top bands. Raise a crest on the front to rear band.
  Match inside crest on the side to side band.
  
• Punch or drill 3/16" holes to attach the bands.
  Attach with #8 screws and nuts.
  Reshape bands to desired shape.
  Mark bands; as to their orientation.
  
• Dish the panels to match your frame; mark each one.
  The panels should lay against the bands with very little rocking.
  Trim if necessary.
  
• Lay out the hole pattern on your frame.
  On the center lines: punch or drill 3/16" all the rivet holes.
  
• Dish the inside retaining straps to match the inside bands.
  Clamp in place and match drill 3/16" in the center position only.
  
• Crease and shape the nasal.
  Clamp and match drill in place.
  
• Clamp each panel individually in place; and match drill.
  Attach with #8 screws and nuts.
  Place flat head screws on the inside sticking out.
  
• Raise the temporarily assembled helm over a mushroom stake.
  Use the rawhide hammer to persuade the pieces to fit better.
  Raise the crest over a more pointed stake.
  
• When satisfied with the shape; dissemble and finish.
  Sand and polish; to your desired finish.
  Reassemble with the screws sticking in.
  Rivet finished helm with 3/16" dome head steel rivets.
  
• Massage the finish bands to panel fit; over the mushroom and crease stake.
  Use a hard wood dowel and hammer.
  Smooth out any metal to metal fit.
  Polish with car paste wax.
  
• If a leather suspension is to be used, do not rivet the front,
  back and side positions. The leather suspension will be riveted in these holes.