CQB Airsoft Helmet build - Halo-airsoft92

[Halo airsoft92]

Hi 405th! This is my first thread on this website, however I do have experience with halo costuming.
So first off I'll introduce myself my name is Luke Taylor, I'm 19, me and some friends have been creating and selling halo costuming for airsoft purposes since 2007.

About this build:
Well this build sadly isnt for myself, it is for a fellow airsoft squad member and it shall go through serious testing to prove usable and safe on an airsoft field.

Plan:
So the plan is to create a fiberglass CQB helmet which has been modified for airsoft efficiency. I will be trying to incorporate fans into the helmet as well as a tactical light and possibly a laser.

Well I know you guys enjoy pics on here so here's the progress so far:

I look forward to any help or constructive criticism

 

[TheRabbit]

What are you planning on doing for the visor area?

 

[Halo airsoft92]

Hi, I'm planning on cutting a motorbike visor and reinforcing it with a backing of metal mesh just incase the visor doesn't withstand a high velocity shot from an airsoft gun such as a sniper.
For now though I've left the paper visor out to save me cutting it out after resining

 

[TheRabbit]

Look into Snell rated racing visors. They are built and tested to withstand a 500 kph lead ball shot into the faceplate.

The face shield penetration test applies to full face motorcycle, special application racing and kart racing helmets. The face shield is affixed to the helmet and shot along the center line in three separate places with an air rifle using a sharp soft lead pellet. Pellet speed will be approximately 500 kph. For both types of shield the pellet must not penetrate, and for the racing helmet any resulting "bump" on the inside of the shield must not exceed 2.5 mm.

 

[Halcyon25]

I had two different Ideas for solving our problem with the normal way for building these helmets for Airsoft. The problem being the fiberglass/bondo combo can be shot right through with as little as 100 fps.

The first idea was to do fiberglass (Fg) with an Aluminium mesh (Am) for reinforsement, layering it something like this from inner to outer. Fg, Fg, Fg, Fg, Am, Fg, Am, Fg, Fg.
this might work, but, its still fiberglass it wont resist 400+ fps for long.

The other idea seems like it'll be easier... Basicly build your helmet like everyone here normally does. Then when that part is done, cut it into smaller pieces and Vacuum form 'em, then secure them together however you see fit. I would however recomend not usng any High Impact Acrylic, Polystyrene or Lexan sheets tinner then 1/8th of an inch. If you go with anything thinner you run the risk of cracking or shooting through the helmet. This is the method I plan on using, I'll use 1/4 inch acrylic for the helmet and 1/8 inch acrylic for the visor.

As for your visor. DO NOT USE MESH, DO NOT USE MESH, DO NOT USE MESH. Most mesh visors will chip the BB and the shrapnel will cause more damage then the initial BB would. espesialy if you play in close CQB style games. You should use somthing like This, This, This, or somthing like those. Or if you want to Vacuum form your own, I wouldnt go thinner then 1/8 inch just because we dont have access to those fancy High impact plastics like Oakley uses...

Hope this helps some.

Chris

Edit: was working on my post when you posted, backing the visor for added security is actually not a bad Idea.

 

[TheRabbit]

You're going to vacuum form 1/4" acrylic? Wouldn't that take some serious horsepower to accomplish?

 

[Halcyon25]

I hope not... otherwise I'll have to make some comprmises...

 

[Halo airsoft92]

Hi thanks for the comments, I am planning to use a high impact motorbike visor, however the metal mesh will be purely for 'just in case' as many players at our airsoft sight tend to use metal mesh alone in their masks.

As for the reinforced fiberglass and metal mesh, that is also a technique we tend to use with our helmets (sorry should have written about the construction of the helmet beforehand).

I won't be vacuum forming the visor because I'm not too sure how well they put up against repeated impacts.
Also I will be giving the helmet extra inner padding incase any bb's will be able to go through all of the layers of fiberglass and mesh

 

[Mstruvmgc]

THis sounds good

 

[shadowyeti032]

I had though about an Halo airsoft helmet before. You will have to be very careful when it come with your shield select. During a major event, like lions claw events, if you alter your visor you can not wear it because it reduces the integrity of the shield itself. My though on this was, if all else fails, wears some ant goggles under the helmet. Guaranteed eye protection.

 

[thorn696]

If you use a Epoxy resin you will get allot more strength.

 

[playdohlord]

There looks like a bit of warping on the back dome shape of the helmet...but shouldn't be anything that can't be sanded out later

 

[Halo airsoft92]

There looks like a bit of warping on the back dome shape of the helmet...but shouldn't be anything that can't be sanded out later

Hi thanks for the concern, I had noticed a bit of warping on the back head section, however due to the cuts on the model I used it is pretty impossible to get the back section clean I shall however be putting and sanding down some bondo on that section in particular for a smoother effect

 

[Halo airsoft92]

I had though about an Halo airsoft helmet before. You will have to be very careful when it come with your shield select. During a major event, like lions claw events, if you alter your visor you can not wear it because it reduces the integrity of the shield itself. My though on this was, if all else fails, wears some ant goggles under the helmet. Guaranteed eye protection.

Hi thanks for the info, I have used particular visors before with mesh backing during airsoft events and they have withstood shots as strong as 480 fps. But I do like the idea of added protection from goggles underneath. I do usually tell clients that I would advise them to use these helmets for longer distance maps only, and that they should use their initiative to take the correct safety procedures beforehand

 

[shadowyeti032]

Good to hear that your a safe player

 

[EdCasey143]

I have absolutely nothing helpful to add, but it's nice to see CQB getting some love.

 

[Halo airsoft92]

Lol thanks for the comment anyways I really appreciate any comments. And in regards to 'being a safe player' I guess I have to make this safe as this isn't going to be my helmet it's for a fellow airsofter, so any accidents leave me to blame

 

[Halo airsoft92]

***update***

Hi thanks for all of the helpful comments so far guys
So I have just been requested a pair of elbow and knee pads from the same fellow airsofter, but mainly only for show rather than protection. I am also planning on using metal mesh reinforced fiberglass for these pieces as they are really just for looking cool

^small scale test model on left, actual elbow pad to the right.

I am currently pepping the knee pads and should be uploading the pics tomorrow

 

[Halo airsoft92]

Sorry for the double post, both knee pads now pepped.
Here's some pics:

 

[Halo airsoft92]

Ok so haven't really made any more progress yet due to a 2 day skirmish. I have however ordered some fiberglass and resin off the Internet and should be receiving them soon.

Have also been sketching a bit because my friend asked me to draw a commando concept helmet for him so he could attempt a 3D model on sketchup