Custodian Helmet - Production

Production

In modern production, hat makers take approximately 30 minutes to complete a single custodian helmet, all of which are made by only four companies: Hobson and Sons (London) Ltd; Christys, of Stockport; Compton Webb (C.W. Headdress Limited), of Oxfordshire; and Helmets Limited, of Wheathampstead.

The initial process begins with the making of the helmet shell using a vacuum forming machine and a metal mould. A sheet of black fortified plastic is heated and then lowered over the mould, where a vacuum pulls the plastic into shape over the mould. Once hardened instantly, a rubber mallet is used to release the plastic from the mould so that the excess plastic around brim of the helmet can be trimmed with a bandsaw and sanded. The helmet's fabric covers are made out of water-repellent wool that are cut in halves and stitched together to give the helmet a distinctive centred, front-to-back seam. Moving down the line of production, glue is applied to both the inside of the fabric cover and the outside surface of the helmet shell, the fabric cover is then steamed and stretched tightly over the shell to prevent buckling. A wooden tool is carefully used to smooth away any air bubbles as well as to ensure the fabric cover is in full contact with the helmet shell; excess fabric is cut away.

Now halfway through production, the helmet is left to dry for several minutes. Once it is dry, black plastic piping is sewn around the brim of the helmet to reinforce it and give it a neater edge. For rosetop and ball helmet styles, the metal fastening prongs or screws of the chrome fixtures are dipped in chalk to mark their positions on the crown of the helmet; holes are then drilled and the fixture is secured. For comb-style helmets, the crest, which has vent holes incorporated into the design, is also fixed by prongs or simply glued into place at the top end of the comb. For all helmet styles, two vent holes are punched on both sides of the helmet and fitted with black metal grommets, making a total of four vent holes.

The adjustable head harness is made out of strips of fabric tape and foam stitched onto a plastic headband; this is then inverted so that a modern-pattern chin-strap assembly and traditional leather chin-strip can be stitched on as well. The harness assembly is lowered into the helmet and secured with an industrial stapler. Depending on the helmet style, a broad plastic band, narrow black metal band, narrow chrome metal band, or broad chrome metal band is wrapped around the helmet and pinned down, concealing the staples. For additional protection, a sponge liner is tucked in to the helmet.

Near the end of production, a hole is drilled on the front end of the helmet and an appropriate police helmet plate is screwed on. The helmet then is sized, cleaned, and inspected. At last, the helmet is labelled and given a good brush to bring up the pile. It is then now finally ready to be shipped on to an awaiting police force.