Cutting a helmet - Wrist Twisters
 
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post #1 of 16 Old 03-02-2010, 02:50 PM Thread Starter
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Cutting a helmet

Hey,

As a somewhat newer rider (7 years) throughout my motorcycle years I've had a few helmets, none of them seriously beat the hell out of other then my dirtbike helmet. Anyways, I still have my helmets, even my first one and I was thinking about mounting them on my wall for my future garage (or like now, my bedroom wall). I wasn't thinking about mounting them the normal way with the front hanging down, I was thinking about cutting them in half and mounting the right side to the wall.

I do have a dermel, I think that would be the best route to cut the shell & possibly the shield clean (with tape of course) but about the rest? Is it just the shell and then styrofoam for the base of the helmet? Does someone have a better idea that might cut the styrofoam cleanly? (old HJC helmets)

Any input would be great!
thanks

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post #2 of 16 Old 03-02-2010, 03:19 PM
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I would use a band saw. Should be able to get a nice straight and clean cut.

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post #3 of 16 Old 03-02-2010, 04:28 PM
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That's a different/interesting idea - I kinda like it. But I think the dremel would be a bit more difficult to use than you're anticipating on the helmet shell - I think it's a bit too small and you'd be shattering cut-off wheels every 10 seconds and end up with a real rough cut edge. I like 919mofo's band-saw idea if you haveone available. Another possibility for the shell is an angle grinder with a good cutting wheel on it - I think it would be more manageable than a Dremel, but not real sure.

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post #4 of 16 Old 03-02-2010, 04:33 PM
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I vote for the bandsaw, if one isn't available would be my next choice. Dremel would take forever


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post #5 of 16 Old 03-02-2010, 04:44 PM
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cool idea epicsoldier, at the end of the football season at my high school we got football helmets cut in half like what you are planning on doing on a big frame with our football pictures around it. I never thought to do something like that with the motorcycle helmets. I would say and angle grinder with a cutoff wheel would work easier than the dremel for the shell.

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post #6 of 16 Old 03-02-2010, 04:53 PM
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Just make sure your head ain't in it when you make your first cut.

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post #7 of 16 Old 03-02-2010, 10:15 PM
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I think I'd use a sawzall with a metal cutting blade, myself. I think an angle-grinder would be a bit overkill...but sometimes overkill works too... Helmets are only made of fiberglass or plastic after all. Give about an 8th of an inch to use finishing the edge when your done, in case there are rough edges. Cutting the visor would be tricky, I'd use a razor knife to score it several times and then just snap it. Since these helmets have a lot of sentimental value, I'd suggest buying a $5 garage-sale helmet to try your technique on, whatever way you decide to go.

I'd like to see some pics when your done with this project, it sounds like a cool idea!





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post #8 of 16 Old 03-03-2010, 05:50 AM
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Cool idea. No advice, but please post pics once you're done and tell us how you've done it.

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post #9 of 16 Old 04-25-2010, 09:18 AM
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did you ever get around to this project, how did it turn out if you did?

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post #10 of 16 Old 04-25-2010, 10:45 AM
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post #11 of 16 Old 04-25-2010, 01:39 PM
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post #12 of 16 Old 04-25-2010, 03:54 PM
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It's possible that a sharp hacksaw would do the job. Curious to hear how it turns out.

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post #13 of 16 Old 04-25-2010, 03:59 PM
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Use the bandsaw or the sawzaw, the angle grinder causes too much heat and melts the plastic and styrofoam. Dremel too small for the job. Just remember to mask out the area for a cleaner cut.

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post #14 of 16 Old 04-25-2010, 06:28 PM
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a damned good jigsaw, i'd recommend a porter cable





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post #15 of 16 Old 04-25-2010, 06:42 PM
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Definitely band saw, definitely.

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post #16 of 16 Old 04-25-2010, 07:11 PM
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One more for band saw. Any rotating blade is bound to melt the Styrofoam and even break it up.

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