OK, Friday I decide, "what the heck" I'm gonna make a Zam helmet this weekend. Saturday morning, at 10:30 a.m., I start by marking and cutting an old fiberglass army helmet liner.
I taped the "openings" closed, and glassed the inside, using the liner as a mold. Well, with the help of bondo, black tooling gel-coat, fiberglass, and good old-fasion elbow grease, this is what I have as of 2:00 p.m. Sunday.
I'm not gonna try to compete with DCB and his ultimate Zam helmet, but it's not a bad start for a day-and-a-half.
I used Wookie's method, and added the brim in fiberglass. It can have the leather glued over it after the helmet is painted. This way, it won't deform if it's packed in a trunk. Besides, I'm no expert at forming leather.