How to Make a Custom Welding Helmet

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A welding helmet is a device that covers the face and eyes to protect them from intense light, sparks or spatter. How to Make a Custom Welding Helmet? Learn how to make your own custom welding helmet with this DIY guide.

Making a custom welding helmet can be an empowering experience for you as well as rewarding in the end.

Before starting you will need to know what is welding helmet and why do you need a custom welding helmet? Let’s dive in and find out.

A welding helmet is a mechanical device, which protects the eyes of a welder from infrared radiation and ultraviolet rays during welding.

The main purpose is to protect the user's eyesight. It also minimizes damage caused by the intense light reflection that can occur inside the helmet itself.

It has two protective portions:  one for viewing through (the lens) and one over it (the shade). The eye-lens portion includes an anti-fogging film with a continuous coating on both sides. Lens material should be made out of polycarbonate or glass, while shade materials vary depending on requirements such as heat protection or peripheral vision needs; common choices are dark plastics like Lexan, molded glass fiber thermoplastic composites in sheet form equipped with lenses, wire mesh, or wire-mesh laminate.

The shade portion of a welding helmet is designed to protect the head and neck from intense light reflections by covering them with dark material like plastic or glass that does not transmit light. The shade should have an opening for viewing (the lens).

A custom welding helmet can be made in many different types of styles depending on individual needs. Some may choose to buy one pre-made while others prefer to create their own design from scratch using materials such as cardboard, paper Mache', clay etcetera which is then coated with more durable substances like latex paint or lacquer before use."

Why do I need a custom welding helmet?

custom welding helmet

A custom welding helmet is designed to be fitted for the user. This ensures that you can see properly and it also offers a great deal of protection from fire, sparks, and electrocution. Once you know your measurements they will be used to make a mold which then becomes the template for creating your helmet as part of the production process.

This will be discussed more in the following sections and is a critical component of any welding project. In addition to protecting you from injury, it also ensures that there are no hazards for those around you as they work near your station. A custom helmet not only protects against sparks and light but also prevents heat loss thanks to its close fit design which keeps air trapped inside the mask during use.

Custom-made welders that can be designed with tinted material or filters so that an appropriate level of protection can be attained based on what's needed by different tasks being performed at hand. This type of headgear can greatly improve both visibility and safety so that fatigue doesn't set in while working long shifts. Safety equipment has been shown to reduce injury rates by up to 50%.

How to make a custom welding helmet?

If you're a welder and feel like your current helmet is too bulky, then this article is for you. You can make a custom welding helmet that will fit your head perfectly with just some simple supplies from the hardware store. This article includes instructions on how to make one as well as what supplies are needed for the project.

It's not difficult at all to make a new welding helmet! All of the tools and materials required can be found at any hardware store-making this an easy DIY project that anyone who has access to these items can complete in their own home workshop. Follow these steps below and start making your own today.

Process is divided into four parts: design, cutting/fitting, padding, and finishing.

Design - Design the helmet to fit your head shape by using paper or cardboard templates that get adjusted as needed.

Cutting - Cut out the templates and make adjustments to them for any personal features that need to be accommodated.

Padding - Tape or glue padding onto the inside of your helmet cover with cotton, foam rubber, batting, or other material. Finish with foam rubber, batting, or other material to make the inside of your helmet cover soft and comfortable.

Finishing- Finish the outside of your welding helmet cover with fabric, plastic film, or vinyl.

Now that you have some knowledge about how to make a welding helmet, what do you think? Are all the steps difficult and time-consuming? It turns out it’s not! In fact, I found these instructions really easy. Let's get started!

Materials you’ll need for the project

For creating a custom welding helmet we need to purchase the following materials:

  • Materials for your welding helmet:

These include a small piece of sheet metal, plastic screen, two pieces of aluminum disk; a hot glue gun to use on the edges of the metal pieces; an X-acto knife or box cutter with fresh blade; and spray paint in any color you want.

We will also need wire clamps to help us attach the clip, as well as a tape measure and masking or rubber bands.

Lastly, we will need a large screwdriver for prying up screen frames in order to remove them from old helmets. This is also helpful if you want to transfer your custom welding helmet design onto an existing one by removing its paint.

  • Materials for your welder:

These include steel wire, gas tanks with MIG welding gun; - Materials to protect surfaces from the heat of the weld: A ThermaShield™ self-adhesive mat or an aluminum sheet is recommended; it can also be any metal surface you want if you don't need to protect the surface from heat.

  • Materials for your welding gloves:

These include a pair of leather gloves, some heavy wire such as steel cable or copper piping; and an X-acto knife with a fresh blade.

They will also need a table or other surface to clamp the wire up, and some pliers.

  • Materials for your welding helmet liner:

You'll need rolls of cotton batting which you can find at any fabric shop; safety pins with large heads that are not too sharp so they won't poke through the fabric; a sewing machine with thread that matches your fabric; and a needle.

  • Materials for the paint job:

To do this, you will need to purchase spray paint in any color of your choice, as well as some tarps or drop cloths from your local hardware store to protect surrounding surfaces while you are painting.

  • Materials for the finishing touches:

These include a variety of things, such as: some electrical tape that matches your color scheme; an iron if you want to put in any details on your helmet like adding numbers or symbols (an X-acto knife can help with this part); and sealant to protect the paint job.

The steps for making your own welding Helmet

Are you tired of the same old boring welding helmet? How about taking a few minutes to make your own custom welding helmet? We’re going to take you through the process in 16 easy steps.


Get your materials together. You will need a welder, sheet metal (preferably 14 gauge or thinner), and some sandpaper.


Measure the circumference of your head with string to determine how wide you want your welding helmet’s brim to be. How about an inch? Cut out two pieces of steel for that measurement plus one inch in length on each side for bending. The width should at least cover the top half of your forehead but no more than three inches above it.


Bend the metal into a circular shape using vise grips while keeping them parallel so they maintain their thickness- this is important! Use paperclips as necessary to keep the ends aligned until cooled down enough not to warp back.


Now weld the metal together. Be sure to wear your welding helmet while you do this! You want to make sure that both pieces are heated evenly and for a sufficient amount of time, so use as many layers of wire as needed to ensure it’s smooth on all sides if possible. If not, take some sandpaper to remove any rough areas or bits with too much material where they meet up- don't forget about getting in between them also


Cut out two more circles from sheet metal measuring ¾ inch wider than your head circumference plus one inch long per side. These will be the ear guards which should overlap just slightly over each other at their centers when worn (less is more).


Wear your welding helmet and line up the edges of one ear guard to mark where you want it to overlap over the other. Weld together again, this time with a wider space in between them so there is less chance they will touch each other when worn while still ensuring that both pieces are heated evenly for a sufficient length of time. Again be sure to wear your welding helmet! How about taking some sandpaper now as well? You don't want any rough bits or uneven areas on either side after all those hours spent wearing it!


Sand down welded sections from step six until smooth. Take off welding mask before doing this if necessary- wouldn’t want sparks flying around and endangering your eyes!


Cut out two more circles from sheet metal measuring ¾ inch wider than the circumference of your head plus one inch long per side. These will be attachments for ear guards- how about an oval shape? How about a large hole in the center with some smaller holes around it? You can do these just like you did before, but make sure to have enough space on either end so they attach securely without overlapping onto each other when worn (less is more). How about taking another break and getting that cutting board ready now too? It's going to get dirty soon...


Attach rivets or bolts to heads of attachment pieces from step eight using excess material from welding helmet. How about punching holes in the center of each piece to do this?


Stick attachments from step nine onto ear guards aligned with marks from earlier. How's that cutting board looking now? Hopefully it has a nice, fresh coat on it!


Attach rivets or bolts to heads of attachment pieces from step ten and put together your welded helmet! How about giving that cutting board one last wipe down before you start on the next steps?


Now cut out two circles measuring ¾ inch wider than the circumference of the head plus one inch long per side. These will be covering for eye guard holes- how about a triangle shape? How about a large hole in the center with some smaller ones around it as well? You can do these just like you did before, but make sure there is enough space so they attach securely without overlapping onto each other when worn (less is more). How's that cutting board looking now too? Hopefully, it has had an extra rinse by now!


Attach rivets or bolts to heads of attachment pieces from step twelve using excess material from the welding helmet. How about punching holes in the center of each piece to do this? How's that cutting board looking now too?! Hopefully, it has had an extra rinse by now.... I told you, didn't I... You'll be glad for all those cleanings later when you're not covered in grease and metal dust!


Stick attachments from step thirteen on eye guard inserts aligned with marks made earlier- how did they turn out? Great job so far, just a few more steps remaining before your custom welding mask is complete! How about taking another break after these next steps are finished? How about grabbing that cutting board for one last time?


Attach rivets or bolts to heads of attachment pieces from step fourteen using excess material from the welding helmet. How did they turn out I can't imagine the suspense is killing you! How's your cutting board looking now, though? Hopefully, it has had an extra rinse by now...


Stick attachments from step fifteen onto eye guard inserts aligned with marks made earlier and put together all three parts of your custom welding mask! Congratulations on completing a very important but also fun project! Time to take off those gloves and slap some water in your face before starting on something else....

Tips and tricks for using your new custom-made welding helmet

After completing your custom-made welding helmet now it's time to wear it, but before wear the helmet please make sure that the welding lens is clean and free of any dirt.

Next step, you want to put on your new custom-made helmet while still in its soft state before it hardens.

Lastly when you are done wearing the helmet simply remove it from the head and wash with a mild soap and water mixture or use ammonia-free cleaner only.


Now that you’ve learned how to make a custom welding mask, don’t forget the importance of safety. Welders can be exposed to high temperatures and harmful fumes when they are wearing their new helmets. Make sure you follow all safety precautions before starting your project.


Can I Paint A Welding Helmet?

Painting a welding helmet may appear to be severe and complicated. However, painting this protective gear is easy and quick. It’s a straightforward procedure that will create your helmet more personal, fashionable, and exceptional. There are many ways to paint your helmet, while you can utilize fluid paint that arrives in a container or jug, fire-resistant spray paint is the most straightforward approach to paint your welding helmet. Begin painting your welding helmet by using a transparent coat onto your protective gear.

Can You Add Stickers On A Welding Helmet?

When somebody chooses to find a new line of work in welding, they may consider including fun and intriguing stickers or decals to their welding cap. While setting a sticker on your welding helmet may appear not to be perilous, or against OSHA principles, it may be causing more damage than good. Knowing the correct method to furnish your welding helmet is vital for safety. Can you add stickers on a welding helmet? As indicated by OSHA standards, they are not completely burned, but there are a few concerns. They clarify that labels should be few and appropriately set. The user must prove that the helmet stickers aren’t meddling with safety in any capacity and aren’t concealing any marks or splits in the helmet.

Why Does Welder Use Masks?

They are essential to forestall arc eye, a painful situation where the cornea is kindled. Welding helmets can likewise prevent retina burns, which can prompt a loss of vision. The two conditions are brought about by unprotected exposure to the profoundly concentrated ultraviolet and infrared beams spread by the welding arc. The real obscuring feature is for the welder’s solace and to shield their eyes from the high-intensity light of the weld and not the IR OR UV.

Why Does Welder Take Milk?

Milk is a remarkable drink. It believed to protect users from body poisoning. Welders get exposed to zinc fumes created by welding stirred steel, the calcium in the milk forestalls the body’s ingestion of the zinc. This sometimes works, but it’s not a solution for extreme exposure to zinc exhaust.

Does A Welding Helmet Go Bad?

It can, in many ways. Relying on how the head helmet is kept, how often it used or how old it is, old it is, it can rust, disintegrate, twist, or break. The eye safety that it provides could likewise blur relying upon the sort of welding helmet. A few welding helmets like those with auto-darkening properties are more delicate than others. A good helmet will have all of these features and comply with the standards that OSHA requires. There is a wide variety of helmet types, and many are a matter of preference for the welder. All are geared to keep your eyes and your head safe from the sparks and UV radiation. Keep these questions and the corresponding answers in mind when picking out a welding helmet, and you’ll have a piece of equipment that will help you professionally for many years to come. A welding helmet is one of the essential pieces of safety equipment, along with safety glasses and boots.

Last Updated on July 12, 2021 by weldinghubs

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