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German M40 restoration

Article about: Hello, I purchased a set of dug-up battlefield helmets not so long ago. They were really rusted so I decided to clean the one that was in a worse condition in some oxalic acid. There wasn't

  1. #1
    ?

    Default German M40 restoration

    Hello,
    I purchased a set of dug-up battlefield helmets not so long ago.
    They were really rusted so I decided to clean the one that was in a worse condition in some oxalic acid.
    There wasn't much paint left and the top of the helmet had few rusted through holes and a bit of the back was chipped off/ missing.
    After, the only thing I found inside the helmet were the numbers 293.
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    So I decided to restore it only because it wasn't in really good condition to start with (Air vents nearly gone, etc).

    I used an anti-rust paint to coat the helmet and to stop further corrosion and oxidization of the metal.

    Then I patched the rusted through parts of the helmet with fibreglass and put on another coat of paint.
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    When it was dry, it was time for the filler.

    I started off with a rough coat of filler to patch any major holes and pits on the surface of the helmet and then i sanded it down using an oscillating multi tool as it allowed for a flat sanding pattern.
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    After that followed a smoothing coat which would patch any smaller pits in the filler and would create a smooth helmet surface.
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    It took about 4 tries with the smoothing filler until a satisfactory look was achieved.

    Because the air vents had almost rusted away completely, I made some replacement ones out of resin.

    I first made a wax model similar to one of the air vents and created a mould of it.
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    Then I used resin to cast a new air vent and after some minor sanding and buffing, I stuck it on to the helmet.
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    Eventually I painted the helmet with a silver paint and then followed with a coat of woodland grey which is probably the closest colour I could get without having a specially made paint.
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    I also textured the helmet using sand (I know they originally used aluminium oxide but I didn't have any).

    Please let me know what you think and how i could try to maybe age it, etc.
    I still have to work on the inside of the helmet.

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  3. #2

    Default

    Looks good ,

  4. #3

    Default

    You've done a heap of work to get it looking like this so I admire your persistence- but I'm a relic man and personally would have left it as it was.
    " When you're chewing on life's gristle, don't grumble, give a whistle "

  5. #4
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    Default

    Seemed a shame to cover it in sand , after you had made such a good job of smoothing it out and making those vents. Could of stuck a decal on the side and had a restored helmet as it would of been fresh from the factory .

  6. #5

    Default

    Amazing process but it is somewhat unfortunately a reversal or history... upsetting the time space continuum? ;-)

  7. #6

    Default

    Good work, almost like craftsmanship!!!

  8. #7

    Default

    gute Arbeit

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