How to Make a Football Helmet Out of Cardboard

To make a football helmet out of cardboard, you need to follow these steps: cut out the helmet pieces from a cardboard box, glue the pieces together, and add padding and a chin strap. Making a DIY football helmet out of cardboard is a fun and inexpensive way to create a costume for Halloween or a sports-themed party.

You don’t need to be an expert in crafting to follow these simple steps. In this article, we’ll walk you through making a football helmet out of cardboard. With a few household supplies and creativity, you can make a unique football helmet to impress your friends and family.

So, let’s dive in and get started!

Materials and Tools: Everything You Need to Make a Cardboard Football Helmet

If you’re a sports enthusiast who loves DIY projects, making a cardboard football helmet is a fun and inexpensive way to show off your creative skills. Here are the materials and tools you’ll need to get started:


  • Corrugated Cardboard Sheets: You will need 4-6 sheets of cardboard, depending on the helmet size you want to make. Make sure the sheets are thick and sturdy.
  • Clear Packing Tape: You will need a lot of tapes to hold the helmet pieces together.
  • Scissors or a Utility Knife: You will use these to cut the cardboard sheets into the desired shapes and sizes.
  • Measuring Tape or Ruler: You will need to measure your head and the cardboard pieces to ensure a good fit.


  • Pencil: You will use it to trace the shapes onto the cardboard sheets.
  • Compass or Round Shape: You will need to create a circle shape for the helmet.
  • Marker: You will use it to mark where to crease the cardboard and label each piece.
  • Heat gun or Hair Dryer: Optional, but can help to soften and mold the cardboard pieces.

You can review the list and ensure you are prepared for this DIY project by providing the materials and tools needed. Once you have everything you need, you can move on to creating the template for your helmet.

Designing the Helmet: Creating a Custom Template for Your Cardboard Football Helmet

Designing your cardboard football helmet is an exciting part of the process. It’s an opportunity to let your creativity shine and, most importantly, ensure the helmet fits properly. The following instructions will guide you through creating a custom template for your cardboard football helmet.

Materials You’ll Need

  • Cardboard
  • Ruler
  • Pencil
  • Scissors
  • Exacto knife
  • Duct tape


  • To begin, it’s essential to measure your head. Place the measuring tape around your head, about 1 inch above your eyebrows, and around the largest part of the back of your head.
  • Sketch an outline of your helmet on a piece of cardboard. Start by drawing the side view of your helmet, followed by the top view. Make sure that the dimensions match your head size.
  • Cut out the cardboard helmet using scissors or an exacto knife.
  • Test the fit by placing the cardboard helmet on your head. Make any necessary adjustments to ensure the helmet fits snugly.
  • Draw and cut out additional pieces on the cardboard helmet to mimic the face mask, earholes, and chin strap.
  • Once you’re satisfied with the template cutouts, use duct tape to connect them to the cardboard helmet. Reinforce the inside and outside of the helmet with duct tape for added support.
  • Trace the entire template onto a new piece of cardboard. This will serve as the actual helmet.
  • Use scissors or an exacto knife to remove the helmet from the cardboard template.
  • Reinforce the inside and outside of the helmet with duct tape, paying extra attention to the parts where the face mask, earholes, and chin strap will be attached.
  • Finally, attach the face mask, earholes, and chin strap to complete your cardboard football helmet.

Creating a custom template for your cardboard football helmet is an important step in helmet-making. Taking the time to ensure your helmet fits correctly will enhance your overall football experience and help keep you safe on the field.

Assembling the Helmet: Putting Together Your Cardboard Football Helmet

  • Now that you have gathered all the required materials and cut out all the cardboard pieces, it’s time to assemble the helmet. Follow these steps to put together your cardboard football helmet.
  • Begin by laying out all the cut-out cardboard pieces on a flat surface.
  • Take the front piece and fold along the crease lines to form the face mask attachment points. Then, glue the bottom tabs to the bottom of the helmet’s sides, matching the front edges.
  • Next, take the back piece and fold along the crease lines to form the back attachment points. Glue the bottom tabs to the helmet’s sides, matching the back edges.
  • After that, attach both the front and back pieces to the sides of the helmet by gluing the top tabs and matching the edges.
  • It’s time to connect the earpieces to the sides of the helmet. Begin by folding along the crease lines to form the attachment tabs. Then, glue the tabs to the helmet’s sides, matching the edges.
  • Once the earpieces are attached, fold down the tabs at the bottom of each earpiece, and glue them to the inside of the helmet.
  • Lastly, it’s time to attach the chin strap to the helmet. Fold along the crease lines to form the attachment tab. Then, glue the tab to the inside of the helmet, matching the chin strap holes.

Congratulations! Your cardboard football helmet is now complete. It’s time to try it on and show it to your friends and family. Creativity and imagination allow you to customize your helmet with your favorite team colors and logos.

Adding Straps and Padding: Ensuring Comfort and Secure Fit

Once you have crafted the cardboard helmet in the desired size and shape, it is essential to add straps and padding to ensure the wearer’s comfort and safety. By adding these additional features, and the helmet will sit securely on the head without falling off or causing discomfort during use.


  • Adding straps to the helmet will ensure a secure fit and prevent the helmet from moving around during use. To make the straps, follow these steps:
  • Measure the chin strap’s length according to the wearer’s head size.
  • Cut two strips of fabric considering the measured length. The fabric must be of sufficient thickness to make the helmet comfortable.
  • Attach one end of the strip to one side of the helmet, then the other to the opposite.
  • Repeat this process for the other strap, positioning it above the ears and attaching it at both helmets’ ends.


Adding padding makes the helmet more comfortable and helps distribute the impact of any possible collisions across the head.

To add padding to the helmet, follow these steps:

  • Cut several pieces of foam sheets according to the helmet size.
  • Apply double-sided tape on the foam sheets to stick them to the helmet’s inner surface, except around the forehead area.
  • The forehead area needs extra cushioning, so apply a thicker layer of padding here.
  • Trim any excess parts of the foam sheet that jut out of the helmet.

Following these simple steps, you can make a comfortable, safe, and secure cardboard helmet with proper padding and straps.

Customization and Finishing Touches: Personalizing Your Cardboard Football Helmet

A cardboard football helmet is a great option for those on a budget or looking to create a unique look. Customizing and adding finishing touches to your helmet can truly make it one-of-a-kind. Here are some tips for personalizing your cardboard football helmet:

Selecting the Design

The design of your helmet should represent your team or personal style. You can create a design representing your favorite sports team or use stickers to create unique patterns. Here are some tips when selecting your design:

  • Use colored duct tape to create stripes or designs.
  • Print out your favorite team’s logo and glue it onto the helmet.
  • Use stencils to create cool designs or shapes.

Adding Extra Protection

While a cardboard helmet may not be able to protect you from hard hits, there are still ways to add extra cushioning. Here are some tips when adding extra protection:

  • Use foam padding inside the helmet to provide more cushioning.
  • Use bubble wrap to add extra padding for protection.
  • Adding a chin strap to the helmet provides more stability to the customization and will look cool, too!

Adding Accessories

Adding accessories can take your helmet customization to the next level. Here are some ideas for accessories:

  • Use colored markers to write your or your team’s name on the back of your helmet.
  • Add colored stick-on jewels to create a bling effect.
  • Add a plastic face guard to the open front.

Adding Color

Adding color to your cardboard helmet is an easy way to personalize it. Here are some tips:

  • Use spray paint to create a base color.
  • Use acrylic paint to create detailed designs, such as numbers or stripes.
  • Use colored duct tape or colored electrical tape to create designs or stripes.

With these tips, you can personalize your cardboard football helmet and create a uniquely designed helmet that will make you the envy of your opponents. Be creative and have fun with your design while staying safe on the field.

Testing, Fit, and Safety Considerations: Ensuring a Secure and Protective Cardboard Football Helmet

Crafting your cardboard football helmet might seem like a fun DIY project, but ensuring that your helmet meets safety standards is crucial.


Before using your cardboard football helmet, testing its durability is essential.

Here are some steps to perform a preliminary test:

  • Wear the helmet and move your head in different directions to ensure it fits snugly.
  • Simulate accidental hits by banging the helmet against a wall or table.
  • Check the helmet for any cracks or damage.

If the helmet doesn’t pass these tests, your cardboard helmet may not be sturdy enough to offer proper protection. Re-evaluate your design and start over.


The fit of the helmet is crucial for player safety. Ensure the helmet provides the following:

  • Full coverage of the head, especially around the forehead, temples, and skull base.
  • A comfortable and snug fit that doesn’t slip or slide.
  • Easy breathing and good visibility.

To achieve the perfect fit, measure your head’s circumference and cut the cardboard accordingly. Use adhesive materials such as duct tape or hot glue to strengthen the helmet.

Safety Considerations

Even though you’re using cardboard as a material, there are safety considerations to remember.

Here are some things to consider when designing your cardboard helmet:

  • Use corrugated cardboard, as it’s more durable than plain cardboard.
  • Make sure your helmet is thick enough to absorb impacts.
  • Add cushioning to the inside of the helmet to offer even more protection.
  • Don’t use any sharp or pointed objects that could cause injury.

Making a cardboard football helmet might seem like a fun project, but ensuring it is safe and secure is essential. Remember to test the helmet’s durability, fit, and safety considerations and adjust as needed. With proper care, your homemade helmet can provide effective protection.


How Do I Make a Football Helmet Out of Cardboard?

To make a football helmet out of cardboard, you must gather the materials, create a template, cut out and tape the pieces, and add painting or other design elements.

What Materials Do I Need for Making a Cardboard Football Helmet?

To make a football helmet, you will need a cardboard box, scissors, a ruler, masking tape, a pencil, and optional materials for decoration, such as paint or stickers.

Can I Make a Football Helmet Out of Any Size Cardboard Box?

The size of the cardboard box you use will determine the size of the football helmet you can make. Before starting the project, measure the box so you know the template size needed.

How Long Does It Take to Make a Cardboard Football Helmet?

The time it takes to make a cardboard football helmet will depend on your experience level and the detail you choose to include. It could take anywhere from one to four hours to complete the project.

Can I Wear the Cardboard Football Helmet for Sports?

No, the cardboard football helmet is not suitable for actual sports play. It is meant for decorative or costume use only. It does not provide sufficient protection in contact sports.


Ultimately, creating a football helmet out of cardboard is not only a creative, fun project but can also serve as a useful tool for game day. With just a few simple steps, some cardboard, and a little creativity, you can create a custom helmet that reflects your team spirit while staying safe on the field.

Remember to take your time when crafting your helmet, paying attention to the details that will ensure a secure and comfortable fit. We hope this guide has helped recruit you to join the ranks of football players who have crafted their bespoke helmets out of cardboard.

So, gather your materials, put on some game day music, and prepare to show off your DIY football gear on the field!

Introducing Al Amin Sagor, a perilously acclaimed author and movie expert. He has a passion for film and is known for his meticulous movie reviews that provide readers with an exhaustive understanding of the latest releases. In addition to reviews, Al Amin Sagor also writes about how to watch movies and the best films to watch across different genres and eras, providing readers with a complete guide to the world of cinema.