I have a helmet that came with the correct large size Bavarian wappen with threaded posts, but the unique wing nuts were missing. Several months ago, I carved some out of s piece of sheet steel, but got the wing length too short. So today, I decided to make correct ones. I chose a piece of .080” (2mm) steel sheet and layed out the shape with an ink marker. I drilled and tapped the center holes with a m3.5 x 0.6 tap. This luckily was the correct size for the wappen studs. I placed the piece in a vise and “carved” the shape out with a Dremel rotary tool using a reinforced abrasive wheel and several hand files. The wings were then bent to a proper angle using a hammer while clamping the rounded center in a vise. My method of replicating the grey phosphate finish is to glass bead the steel and then spray clear flat dullcoat lacquer. The project took 3 hours. The wing nut on the right is the one made previously with too short wings. The 2 on left are the new ones.
Ron
Ron
