Re-forming / Re-shaping Warped Leather Helmets

kaiserzeit

New member
Gentlemen,

It is probably best if this entry becomes a "work in progress" until everyone is satisfied that we have it right. I particularly defer to Brian and Tony in this regard.

Here is my shot at "How to refurbish a warped Pickelhaube." I warn you, this approach sounds scarey but, if you move with care, is just fine:

1) First off, this method relates to a helmet with an enlisted man's style, leather only, liner (not an officer's silk and leather liner) and no paper sticker tags.

2) Secondly, think of how your wife would treat her hands:
- She would not put her hands in scalding hot water or expose her hands to hot, dry air for extended periods.
- She probably uses some sort of skin conditioner to soften and moisturise her hands.

****The same psychology applies to 100-year old Pickelhaubes.

3) Remove wappen, chinscales and cockades and (if it can be done easily) the spike.

For clarity, it is risky to bend and re-bend metal tabs on the backs of metal helmet parts. These tabs often can only be bent and re-bent 3 or 4 times before they break.

4) Dunk the helmet in a pailful of warm (not hot) water and let it soak for just long enough to become pliable. It doesn't take long, only a few minutes.

5) Now is a good time to clean off any crud on your helmet with soft bristle brush and some saddle soap. Rinse with clean warm water after cleaning.

6) Place the helmet on a round/oval form to approximate the shape of the human head. Best is something plastic, glazed pottery or glass which will not transfer anything to the leather (i.e. not wood). My favourite is one of my wife's kitchen bowls (inverted) that just happens to be the right size.

Leave in a dark, dry, not too warm place (back shelf of a closet) for several days and allow the helmet to dry naturally - no heat source, no hair dryers. Don't rush this process or the leather will shrink like you wouldn't believe.

7) Re-condition the leather with a good quality leather conditioner like Lexol (a U.S. brand) or even some un-scented glycerine (the stuff our Grannies used to use on their skin).

Don't overdo the conditioner, a little bit goes a long way. You are better to do several light applications, allowing the helmet to sit overnight between applications, rather than a few heavy applications.

8) After the conditioner has had a chance to soak in, you can re-assemble your helmet and you're done!

There, I hope this helps.

Please, if you feel strongly that anything in the above could cause damage to a helmet, do not hesitate to correct me. Once we get this recipe 'right' it can be a standard method that members can use with confidence.

Cheers,

Laurie
 
kaiserzeit said:
4) Dunk the helmet in a pailful of warm (not hot) water and let it soak for just long enough to become pliable. It doesn't take long, only a few minutes.

7) Re-condition the leather with a good quality leather conditioner like Lexol

Laurie, with all due respect, I absolutely do not agree with dunking a helmet in water or applying Lexol. Anyone that wants to do this, would be better off to stomp on the helmet and just get it over with. My advice, if you want to fix a helmet, send it to Brian. This is how he pays for this Forum. T
 
Hi Tony,

Fair comments.

On balance, I'll field them one at a time:

4) Dunking in water - I mean for a short space of time, long enough to make the leather pliable, not soak it to mush. Guess how the helmet originally got its form?

Or, are you more concerned about the outside finish? My motivation is, any helmet that has suffered severe warping will probably need its finish re-annealed/re-applied anyway.

With due respect to Brian, who does masterful work, how would you deal with a warping problem?

7) Conditioning the leather - I feel the need to defend this point more vigorously. Coming out of original manufacture nye on 100 years ago, the leather in these helmets was already pretty dry. Now, let it dry some more over the intervening decades and it will be prone to cracking and or dry rot. A light conditioning, particularly via the inside surface, should be highly beneficial to replace the oils that have dried away over the years.

****To all those who might not have known, our sponsor for this wonderful forum, Brian Loree, does helmet restoration on the side; and does beautiful work. If you have a high-value helmet in need of some TLC, Brian is your man.****

My thanks to Brian for his generosity and graciously tolerating outspoken creatures like myself.

Cheers,

Laurie
 
The heretic with the funny name again. Mike, himself, actually came up with a very valid technique for re-forming warped helmets. Here it is:

I re-formed a sunken crown by placing a layer of 'Gortex' insde the shell and filling the shell with damp tissue and sealing for several hours in a large plastic bag. The moisture dosent touch the leather but the gortex allows water vapour to penetrate and gently soften the skull. Put on a headform and leave to dry. It worked great.

I don't know, I think his approach is a whole lot more elegant than mine. I would emphasize, though, that you definitely do not want to rush the drying and the skull form should be plastic, glazed potter or glass, not wood.

And, (Never say die!) Don't forget the leather conditioning.

Other than that, I think Mike is spot-on!

Cheers,

Laurie
 
The only information I have seen in print is in Dr. Eric J Johansson's book "Pickelhauben". He has quite a discussion (pg 157-165) on this but his method is essentually the same as Laurie. Bill
 
How would I re-from a Pickelhaube? I would not buy a Pickelhaube that needed reforming. Keep in mind I am a soldier so the "not all of us can afford to do this" line does not work with me. My mantra: It is better to save your money and buy quality.

"Guess how the helmet originally got its from?" Laurie, this is restoration, not building a helmet. Allowing a skull to become permeated in water and there is a very high probablity all the lacquer will flake off. I have heard of some very nice helmets, mostly Bayern with cruciform spike bases, that were ruined with this very advice given by Johansson as Bill pointed out. This is the same genius who recommended removing all parts and spraying them with lacquer. I spent an entire weekend removing the old yellowed lacquer from a Kürassier Metallhelm after someone followed that brilliant idea.

Lexol is an excellent product for conditioning liners. But by placing it on the leather of the skull, you run the risk again of having the lacquer peel off. I once saw a helmet that had been "conditioned" so that it was actually soft. Like a shoe!

My advice, buy a humidity gauge and keep your humidity at 50%. This is what every reputable museum in the world does.

And once again, Brian has the skill, knowledge, experience, tools, and heuristics to fix helmets safely. I would not recommend anyone try this unless they are willing to turn a misshapen helmet into a ruined helmet. Hey, you can always sell the Wappen.........
 
Hi Tony!

Thank you for your response.

Some excellent snippets of advice are tucked away there. Seriously folks, if someone doesn't ask a few stupid questions or throw some haywire ideas out, how the Heck else are we going to learn?

Some of us are weekend handymen. That's why I'm pushing this barrow.

What have we learned thus far?:

1) If a helmet has stickers or a silk officer's liner, treat with extreme care.

2) If a helmet has a lacquer finish, don't do anything (like dunking it in water) that might cause the finish to flake away or discolour.

3) Save the dunking in water trick or its variants for helmets where the lacquer finish doesn't matter any more and is going to need to be re-done anyway.

4) Don't put clear lacquer on metal parts. With age, the lacquer discolours and looks really crappy.

5) Don't unbend and re-bend metal tabs on badges and other metal parts. You can do that 3 or 4 times and then they die.

6) Court is still out on conditioning leather. Tony makes a good point: If you go wild with the conditioner on a lacquered helmet, the conditioner will find its way through the leather (the wick effect) and lift the lacquer from the back side.

The downside is: if you don't condition dry leather, it can crack. Maybe this one is a judgment call.

Tony, recognizing good advice when I see it, I have saved the three most important points for last:

7) Keep your helmets in a closed cabinet and keep its humidity at 50%.

To Tony: Where would one buy a humidity gauge?

8) Wherever possible, save your hard-earned cash and buy the best quality example you can afford. - That holds true for whatever area of collecting you engage in.

9) If, contrary to above 8) you have put your hard-earned into a helmet that needs some restoration work, you are best-served to talk to Brian. He has gone to a lot of trouble to learn how to do it right.

All the best,

Laurie
 
kaiserzeit said:
Where would one buy a humidity gauge?

Anywhere. Sears, Wal-mart, you name it. Mine cost me $35 at Sears. Trust me, the best $35 you will ever spend.

guage.jpg
 
I would like to second all of Tony's comments on helmet restoration.
I learned a valuable rule years ago from a museum conservator concerning conditioning old leather. "if you can pour it do not put it on old leather."

Reservist1
 
Once again Tony has covered some of this on his web site. I would highly recommend the chapter on "Conservation and Display of Antique Leather Headgear". As collectors we are caretakers of these artifacts so we need to do our upmost to preserve them for the next generation. Bill
 
Hello All:
Thanks to Laurie for initiating this discussion and his willingness to take some flak. My name has been mentioned several times in this thread so I had better comment. First, I am not the guru of restoration by any means. As far as the use of water and dunking goes, I tired it once early on following Johanssens' suggestions but it destroyed the scrapper I was working on. Fortunately, I did not lose a quality helmet. Even when I applied water to a specific sunken area of a helmet I often lost sections of original shellac finish. Replacing finish layer by layer is "VERY" time consuming and I do not want to go there unless the piece has already lost finish.
What I have been using to soften the leather is a light aplication of rubbing alcohol (enough to soften the leather) applied to the specific area. This does not produce flaking of finish but it does stain the inside of the shell where it is applied. The area is wet then blocked on a head form using bumper pads to force out the depression in the shell. I use large rubber bands to force the shell down on the bumpers thus pushing the shell back into position. I have been nervous about using the alcohol because, I know that it dries out the leather. However, I know of no other alternative except water which does not work , dries out the leather and also produces stains.
Spikey Mikey has shared his Gortex method with me and I want to try that next. It seems to me to be a gentler method and thanks to Tony I already have my piece of Gortex ready.
As to brass split brads, once I have taken them off very carefully, I heat the prongs red hot with my blow torch. This anneals the molecules in the metal and makes it soft once again. The prongs will not break when spread unless the metal was already cracked. I do this with all types of brads. I even do this with visor trim which has become bent or twisted.
I use Lexol on OR liners. I do not apply anything to the inside of the shell except in the case of pushed in sections. I use a mild solution of dish soap and a cloth to wipe out the inside of helmets. In my reforming, I use styrofoam heads, antique wooden hat forms and antique wooden hat stretchers. The hat stretchers are the most valuable because they are adjustable.
Like Tony, I control the humidity in my collection room and I use a humidity gauge. So now you know some of my secrets...Brian
 
Thanks for all this you guy's. It helps a hell of a lot!
I agree with tony's 'buy quality' principle and have tried to adhere to that rule. However this particular piece is not too deformed - I could live with that aspect of it - it's the slight dryness of the liner that bothers me most - so what do i use for that? Lexol? Tony reckons not.Cant get it in france anyhow. I may just gently place it on a headform and leave it there to go it's own way over time. It also has a nice label inside thats very fragile with the soldiers name and unit so maybe keep off the steam treatment eh?
And yes, Brian is the man - an artist no less!!
 
spikeymikey said:
//t's the slight dryness of the liner that bothers me most - so what do i use for that? Lexol? Tony reckons not.

Mike, I have used Lexol on liners if the liner was all dried and crumpled to get it back into shape. Lexol, however, will dry out and the liner is stiff again, but at least it is back into the form it should be. If you want some, e-mail me at home as there is a shop here in town that sells it. T
 
Thank you, Brian and Tony.

This little thread is evolving very nicely, if I do say so.

Brian, might it be possible to pin it in a "Reference" folder or something like that?

Cheers,

Laurie
 
Oh God!

It's that nitwit again with his leather conditioners!

A sword collecting friend of mine on a par with Col. Ron and Mr. X suggests a family of products called Pecard's:

http://www.pecard.com/

They have a distributor in Britain:

http://www.antiqueleatherdressing.co.uk/

More good stuff to know about.

Cheers,

Laurie
 
You liked the sound of the 'Gortex' technique, yes? Do you think that the water vapour would set up any rotting process down the line at all? I dont see why myself but I'm no scientist! They use gortex at the Brit. Museum to re-shape 'haubes. Also only ever use "Renaissance Wax" on the outer shell to finish the thing. I know tony advocates "Kiwi" shoe polish but the head conservator at the Brit.Mus. said that Renaissance wax was kinder, as shoe polish contains Turpentine and stuff.

Cheers mate,

Mike.

Hi Mike.

I think the Gortex trick is a winner.

Whereas prolonged dank, moist conditions might lead to mould, I don't think that what you are proposing, to re-form a helmet, would pose an undue risk of mould.

Waxes and polishes are a real nest of snakes. I don't know the details, but there is a group of polishes containing silicone, which the pros really don't like. My understanding is that the best ones for our purpose are beeswax- based and don't contain any turps or other nasties.

Turpentine is a key product of furniture waxes - cleans the wood and acts as a solvent for the wax; hence, that knocks many well-known furniture products off the list.

I touched lightly on the subject of waxes in me comments about verdegris, a high-end car wax (with a beeswax base????), containing carnauba might also be useful for leather, too. Sword and gun collectors swear by this technique for metal parts.

I agree with you museum friend, another downside of bootpolish is that it contains alcohol so will tend to draw moisture out of the leather.

What does your museum connection have to say about conditioning leather in 'haubes?

A devil's advocate point I thought of making was how come we don't see much 200-year old leather around? At least part of the answer might be that most of it has dried out and crumbled to dust.

Cheers,

Laurie
 
Any Brandname that is available here in Ontario that would be good for the alternate to total refinnish. The wax or polish ,Ithink Polish as colour would be an issue.
On the point of collecting .I have only 3 haubes ,but I due collect other areas of Militaria . I will try to fill out holes I try to get what I can afford ,If it is a middleshelf item thats what I get .This applies to the hard to find sections of any areas I collect. This is my mantra on collecting.
Mark G.
 
I have used Pecards in the past but find it very greasey much like Dubbin. I prefer Lexol for liners now. I used Spikeys gortex, wet news paper and plastic bag technique. It certainly softened up the shell without loss of finish. I will be using this method from now on. Brian
 
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