Made the base shape out of cardboard! Then I covered it in expanding foam and let it cure (which the bottle says to leave for about 8 hours). It foams up when first applied but don’t put on too much at first!
The foam expands a lot when it is dried. I recommend putting on a coat and letting it cure, then cutting it into the shape you want and cutting again. This will be easier than trying to cut through a giant foamy monster! Also wear gloves since the foam is made out of weird chemicals and will irritate your skin. I forgot to put them on the first time and my arms got all itchy :<
Carved a hollow part in the middle where the helm would fit over my forehead. I also made a base helm/band that the “horns” would attach to! I made this band out of craft foam and worbla. It was curved so it fit right over my head.
Important!! If you are ever making a cosplay helmet, make sure it fits to your head + wig! If you fit it to your head like normal, it will be too small when you fit it over your wig!
Covered my helm with painters tape. Would have used paper mache but I was running out of time. The helmet is massive on my head but fits perfectly with the wig on! It had a tendency to tip forwards because I didn’t have time to attach clips at the back so it fit more snugly to my head.
Used small strips of worbla and wrapped them around the horns. This gave a more demonic look I think, because they looked like actual horns rather than part of a helmet. It looked bumpy at first but I heated the worbla and used a knife to press down the edges so they melted flat.
Didn’t have time to sand it either, so I tried melting and pressing down the edges as flat as they would go and then used a spray gesso to prime my helmet.
I don’t have photos of the painting process because it was done at 1am the night before I wore Syndra, but I used a glue gun for the raised parts at the front of her helmet. I melted together some worbla scraps to make the main shape of her helmet jewel/eye thing. Primed with spray gesso, and painted with acrylic paint! I forgot about the little flap things at the very top of the helmet so I’ll add those next time.
Again, I would have liked to have better primed/ varnished this helmet if I had the time, but I’ll leave that for touchups for the next convention.