Inside The Made To Order Process For A Handcrafted Helmet

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A jacket built for riding, rather than a fashion jacket that merely looks the part, adds abrasion resistance across the shoulders and elbows, and many include pockets for armour inserts. Boots that cover the ankle protect a joint that takes real force in an off, and trousers or riding jeans extend that same protection down the leg.

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.

Daily wear also plays a part. Sweat, sunscreen and regular use all shorten a helmet's working life, so riders who use a helmet every day should expect to replace it sooner than someone who rides occasionally.

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.