The document describes the steps to make a polyester helmet, including defining head measurements, cutting a PU foam block to shape, adding layers of glass mat and polyester resin to the foam, sanding edges, and finishing the helmet. Key steps are cutting the foam to shape, laying up layers of glass mat and resin on the foam, and cutting and sanding the finished helmet edges.

1. Making of a polyester helmet

2. Defining the measures of the head

3. PU-Foam Block

4. Draw Centerlines: references

5. Cut the foam
Use paper tape as a reference and guide
Cut as much as possible: less irritating dust

6. Finish the topview

7. Sideview: draw on both sides

8. Round up by sanding

9. Fix PU-form on the table

10. Tear glass mat into pieces

11. Make sure you prepared everything

12. Prepare the Resin

13. Stir well

14. Paint PU-form with polyester-resin

15. Add Glasmat and push it with roller

16. Lay up all layers and impregnate with resin

17. Cutting the edges

18. Cut off the edges

19. Turn up side down

20. Done