Tired of that old brain bucket? Before you rush out and make a new purchase, try this cool modification for a cool new look, and save your cash for chrome!

Tools Required: Sewing machine, scissors, heatgun / hair dryer, drill

The Pattern

First a pattern needs to be made of the helmet. This was the hard part, patterning a "ball" to be shed with with a flat material. I used some winter marine shrink-wrap, heated it with a heat gun but a butane torch will also work with caution! If shrink-wrap is not available, wrap the helmet in a plastic bag and then cover the helmet in duct-tape. (The plastic bag is so the tape doesn't stick to the helmet.)

Now mark the pattern lines as shown and mark the edge of the helmet. Label seams with alignment marks so as to assure proper seam alignment when sewing.

The pattern can now be removed from the helmet and cut into three sections. Be sure you mark all the pieces so you put the puzzle back in the right order when sewing.

Lay out your pattern on the Leather. Use a thin, pliable material as it really does not have to be too thick. (This mod is for *looks*, not for safety! ;-). Leather is the obvious choice, but marine grade vinyl (imitation leather) may also be used.

Mark and label all the seam lines and also the alignment marks to match the pattern markings.

I then drew another line 1 inch from the traced line of the helmet bottom . This is to allow extra material for grasping when applying the new skin.

The Sewing

Sew the seams together, face to face.

Once both the seams are completed you are now ready to turn the fabric inside out (or outside in?) and finish the seams.

Fold the seam over tight to the previous stitch and double stitch down all the seams.

The Gluing

Now you need to remove any vents and snaps you may have for a visor. Drill off the head of the rivet holding down any visor snaps, or vise grips do a nice job of taking care of things. ;-) Now you need to remove the platsic trim piece on the edge of the helmet. (This is where selecting a thinner covering material will be a great advantage when replacing the trim!) Now your ready for glue!

A good quality marine adhesive should be used as at some time you will be caught in a good soaker! ;-)

Don't try to do the entire application in one shot. First spray a small spot at the top of the helmet and on the fabric (the glue should be allowed to set as per the direction on the can) and start from the top of the helmet. THIS WILL ALLOW YOU TO SEE HOW EVERYTHING IS GOING TO LINE UP.

Spray and stick one section at a time. Trying to adhere too much at once can be tricky, take your time and pull the fabric down tight. The heat gun you used already with the shrink-wrap or a hairdryer can be used to soften the leather and allow the normally flat material to conform to the round surface. Once the leather is all finished and set, you can now replace the vents if you want and install new visor snaps. (Available at your local marine canvas/upholstery shop or fabric retailer.)

Replace the trim piece around the edge of the helmet. You may find with the additional thickness of the leather, some adhesive such as super glue may be required.

The finished article... Shaweet!

I'd rate this project as a fairly easy one if you are familiar with a sewing machine. [Or get the missus to give you a hand! ~ Ed] If you goof up too bad, just throw it in the trash and go splurge on a nice new Bell leather helmet! :-)

If you decide to do this modification, feel free to email me and I'll give you any tips I can to help you get through it.

- Mike.