Inside The Made To Order Process For A Handcrafted Helmet

This is slower than fully automated manufacturing, and that is the point. A handcrafted shell trades speed for a level of finish and individual attention that a purely machine made helmet does not offer.

A made to order helmet starts long before any material is cut. Measurements are taken, the intended use of the helmet is discussed, and a rider works with the maker to settle on a shell, lining and finish that suit them specifically, rather than picking from fixed stock sizes.

Certification is not a formality. It is the baseline that separates a genuine protective helmet from something that only looks the part. Any helmet worth wearing on the road should carry a current, verifiable certification.

To see the certification behind our own range, visit returnofthecaferacers.com.

A leather trimmed helmet needs a little more attention than a plain shell, but the upkeep is straightforward. Dust and light dirt can be wiped away with a soft, dry cloth, and any marks are best treated with a product made for leather rather than general household cleaners, which can dry the material out over time.

Once the shell is formed and cured, it moves through finishing: sanding, painting or leather trimming, and fitting the internal padding and retention system. Every stage is checked before the next begins, since a fault caught early is far cheaper to fix than one found at the end.