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jamesjordan
Aug 34 min read

DIY Guide: Sanding Down and Custom Painting Your Old Motorcycle Helmet


I was hanging in the Legendary USA HQ the other day in Brick, NJ when a rider came in with a sick helmet. The paint job was almost looked like a carbon fiber gold & black with intricate sprayed patterns. I inquired about it and he said he did it himself. This led to a lot of questions and here's what I've come to figure out if anyone wants to customize their helmets paint job. If you have an old motorcycle helmet that's seen better days, don't toss it out just yet. With a bit of creativity and elbow grease, you can transform it into a custom piece that reflects your personal style. This DIY guide will walk you through the steps of sanding down and custom painting your helmet, giving it a new lease on life.

Materials Needed:

  • Old motorcycle helmet

  • Screwdriver (for removing any detachable parts)

  • Sandpaper (220-grit and 400-grit)

  • Masking tape

  • Plastic drop cloth or newspaper (for covering your work area)

  • Spray primer (suitable for plastic or fiberglass)

  • Spray paint (in your desired colors)

  • Clear coat spray (for protection and shine)

  • Painter’s tape

  • Gloves

  • Safety glasses

  • Respirator mask (for safety during sanding and painting)

  • Soft cloth

  • Mild soap and water

Step-by-Step Instructions:

1. Preparation

Safety First:

  • Before you begin, ensure you're working in a well-ventilated area. Wear safety glasses, gloves, and a respirator mask to protect yourself from dust and fumes.

Clean the Helmet:

  • Remove any dirt, grease, or stickers from the helmet. Use mild soap and water to clean the surface thoroughly. Dry the helmet with a soft cloth.

Disassemble the Helmet:

  • If your helmet has any detachable parts like visors, straps, or padding, remove them using a screwdriver. This will make the sanding and painting process easier and more efficient.

2. Sanding the Helmet

Start with 220-Grit Sandpaper:

  • Begin sanding the entire surface of the helmet using 220-grit sandpaper. This will remove the existing paint and create a smooth surface for the new paint to adhere to. Sand until the surface feels smooth and even.

Switch to 400-Grit Sandpaper:

  • After the initial sanding, switch to 400-grit sandpaper for a finer finish. This will help eliminate any remaining rough spots and prepare the surface for priming.

Clean the Helmet Again:

  • Wipe down the helmet with a damp cloth to remove any sanding dust. Allow it to dry completely before moving on to the next step.

3. Priming the Helmet

Mask Off Areas:

  • Use masking tape and plastic drop cloth or newspaper to cover any areas you don't want to paint, such as the inside of the helmet or any logos you wish to preserve.

Apply Primer:

  • Shake the spray primer can well and apply a light, even coat to the helmet. Hold the can about 6-8 inches away from the surface. Allow the primer to dry according to the manufacturer’s instructions. Apply a second coat if necessary for full coverage.

4. Painting the Helmet

Base Coat:

  • Choose your base color and spray a light, even coat over the entire helmet. Hold the can 6-8 inches away and use smooth, sweeping motions. Allow the paint to dry completely before applying additional coats. Repeat this process until you achieve your desired color intensity.

Design and Detail:

  • Once the base coat is dry, use painter’s tape to create designs or patterns on the helmet. You can use additional colors to add stripes, shapes, or other custom designs. Apply the paint in thin, even layers, allowing each coat to dry fully before adding the next.

5. Finishing Touches

Clear Coat:

  • After you’re satisfied with the paint job and it’s completely dry, apply a clear coat to protect the paint and give the helmet a glossy finish. Spray a light, even layer of clear coat, holding the can about 6-8 inches away. Allow it to dry completely and apply a second coat for added protection.

Reassemble the Helmet:

  • Once the clear coat is fully dry, remove the masking tape and reattach any parts you previously removed. Ensure everything is securely in place.

6. Final Inspection

Check Your Work:

  • Inspect the helmet for any missed spots or imperfections. Touch up as needed and allow any additional paint to dry completely.

Enjoy Your Custom Helmet:

Tips and Tricks:

  • Test Your Paint: Before starting on your helmet, test your paint colors and techniques on a small, inconspicuous area or a scrap piece of material.

  • Thin Layers: Apply paint in thin layers to avoid drips and ensure a smooth finish.

  • Patience is Key: Allow ample drying time between coats of primer, paint, and clear coat for the best results.

With these steps, you can give your old motorcycle helmet a fresh, personalized look. Not only will you have a helmet that stands out, but you'll also have the satisfaction of knowing you created it yourself. Happy riding!


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