This project is rolling along pretty well now so I wanted to share what I'm doing. This is one of the inexpensive GDFB sallets. There's plenty to complain about on the stock sallet but the price is fair. The challenge is to then add value and utility by transforming it in several ways.

First, although the shape is okay, it's HUGE--much larger than what I typically see in Italian export sallets of the mid-15th c. The size, depth and weight are more in line with later German and Austrian sallets so I've followed that path, trimming the visor to a later style (and shedding weight in the process). I'm adding a German-style spring catch as well, which you can see partially finished here. You can spot lots of other changes, I'm sure, including the beginnings of a new and historically appropriate liner (rivet holes, handmade washers, lining band, etc.)

If GDFB would take this same shape and size but leave the front closed to create one of the more typical German deep one-piece sallets, I'll be delighted. Until then, this one will do.

This is not the final finish. I'll do that just before stitching the liner to the lining band. Although the finish in the catalog shot (first image, below) looks soft, this helmet was actually pretty highly finished off-the-shelf. Very shiny, but in a cheap-looking way. The final finish will be somewhere between that and the very soft current finish.

The new visor pivots are galvanized lag bolts, with the heads reshaped in the style of an example in the Metropolitan Museum of Art. Those still need a small amount of detailing.

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correction: These are actually carriage bolts. You could use lag bolts for the taller pivot types but carriage bolts are perfect for this flatter type. Some later pivots look like they were bought at Lowe's!

I'm ready to install the lining band and liner. I grabbed a quick photo before finishing the liner to show the effect of quilting. The quilted bit is on top in this image. At right, you can just make out a sample of the four layers of organic cotton batting I used. The flattening effect is hard to judge, so be sure to use more padding layers than you think you need.

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Introducing the new Apple iSallet!

Well...no, actually. I just installed the liner last night and grabbed a quick shot. The size and shape of the bowl is such that I need to add additional side panels to the liner. Even so, there's already a world of difference between the sallet as it is and the sallet as it was. :D

As you can see, I haven't yet cut down the visor pivot bolts or installed the straps. I also need to add some subtle filing along the top edge of the visor in imitation of a similar visor from Rhodes. Then I'll do some cleanup work on the finish.

Not far to go, now!

Nobody's yet hit me with an offer of a cheap bevor! Still waiting.... :D

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Saved to favorites.

I have been debating as to whether to buy this sallet and modify it similarly or to purchase the GDFB Jaw Bone Visor and try to make it resemble the sallet found at Witton-le-Wear. I'm leaning toward the second option, but can't find any decent pictures of the piece, so I'm still up in the air. Maybe I'll do both. :lol:

Anyway, this thread is interesting and helps me get a feel for the product and what can be done with it, so thanks for that.

I think the jawbone versions could be improved by moving the pivot back just enough to elevate the front and close the sight a bit. Those helmets are probably much lighter than this one, which remains a beast even with so much cut off the visor. I pretty much just added the weight back in the rivets.

Looks good. An often overlooked thing about a kit is details like these, too many just get off the shelf and think that's the be all end all of kitting. But this brings a really decent helmet with some minor issues up to museum quality.

Here's the finished liner. I'll call it a "duplex" liner :D If you look closely you can see that there's the usual one-piece liner reinforced by additional triangles at the brow and sides. I'd like to say that this is some rare historical method but it's really just how I'm coping with the very large and round bowl of this helmet. The brow piece covers the gap created by patterning the liner on my head rather than on the large bowl (came up slightly short as a result). The side pieces simply help with the fit because while the bowl is quite round my head is narrow. There's still too much side space, but the fit is much improved. I have no idea if this was ever done, historically, but it's the easiest way to adjust the circumference of a helmet that wasn't made to fit the wearer.

I've cut the straps. Now I just have to dye them, trim, pierce, mount the buckle and install. Final polish and I'm done. Maybe next week!

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DONE! First and third images below are the "before" shots.

I'm calling this a German or Austrian sallet of ca. 1480. My wish--GDFB produces a deep, integral visor sallet of this type. It'd be simpler and better overall, as the visor is the main problem with the model shown here. Some things I didn't want to bother with--creating the step at the ends of the sight, for example. I also didn't fuss over the finish so there are irregularities, file marks, etc. It's not meant to be a fine sallet. I intended to do the buckle in historical style, with the strap end the width of the buckle plate. I liked the look of the wide red strap under the narrow brass buckle plate, though, so I left it like that. The buckle itself is the original from the helmet, with only some filing to round the bar. Tongue is original, too, but modified.

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Really nice Sean! You really did an awesome job with your modifications!

Almost makes me sad to look at my GDFB helm. lol. :lol:

Was is difficult to decorate the carriage bolt heads like that? And what did you use? Just sandpaper?

A shot of the finished pivot/bolt. You can see the asymmetry of the pivot and indifferent finish.

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Very nice work! You took a stock "ho-hum" sallet and turned it into something that would pass at a living history level. :)

I really like your modification to the visor that adds a little more "swoop" on the back curve between the pivot and bottom. :cool:

Hello Sean,

I like your flower shaped bolt best. It's one precious little detail, which no other GDFB helmet has. Too bad you couldn't change the pivot, which is set too high on the dome from the beginning. Keep up the good work.

Thomas

I nearly exclusivly wear great helms, but I must say that I admire your enthusiasm on this project. You have an awsome helmet now.

If you are that skilled you might as well make the whole sallet. The visor is the most intricate bit.

Stunning transformation btw.