Witch King of Angmar Helmet
This is a cosplay helmet of the Witch King of Angmar from the Lord of the Rings Trilogy. This helmet was made out of EVA foam from a template by SKS Props (https://www.youtube.com/watch?v=u3S78i4XEvc).
I used a variety of techniques to make the surface of the foam to look like steel. It was a simple process to build the helmet, but it was by no means easy. Overall I am really happy with how this project turned out. It has high fidelity to the original design, and it was great to see the transformation from raw foam to the final helmet.
Here is a reference picture of the Witch King of Angmar: https://shorturl.at/dntwQ
Here is the template from SKS Props. I cut out the template, traced it onto the foam, then cut it out with both a Utility Knife and a Bandsaw.
Using a Hand Dremel, I cut out grooves on the backside of the foam cut outs. I then used a Heat Gun to apply heat and bend the foam over the grooves. I filled the space with hot glue and let it dry. This technique created creases in the foam that turned simple shapes into the complex forms of the helmet.
I repeated the process of making creases in key areas of the helmet, and then I used Super Glue with an Accelerator to combine all the pieces together. I cut the headband to ensure that it would fit my head.
Next I used the Hand Dremel to round out the spikes in the helmet.
I softened the edges of the foam with the Hand Dremel to make helmet appear thinner. I then used the Hand Dremel to create punctures and texture in the surface. This made the helmet look war-torn and well used.
I hot-glued all the spikes together, and then attached them to the helmet to create his crown of spikes.
To create even more texture, I applied heat with the Heat Gun to the helmet and then firmly pressed crinkled aluminum foil into the surface. This technique worked well for creating scratches and rough spots in the helmet.
Finally, I put 2-3 coats of Mod Podge over the helmet to seal the foam and add further texture. When the Mod Podge dried, I painted the helmet with Spray Paint. Once the paint dried the project was done, and Mordor ready!
