1. Diagnosis: How is the inlay secured?
Historical (Sewn In): With authentic replicas (like medieval bassinets), the inlay is often fastened to a leather band (arming band) that's riveted to the helm.
Modern (Screwed/Riveted): With modern armour replicas, the inlay is often attached directly with rivets or bolts to the inside of the helm.
2. The Method: Step-by-Step
Step 1: Positioning (The "Fit-Check")
Put the helm on with the inlay inside. Determine the correct height.
The rule: Your eyes should be positioned exactly at the height of the visor opening or the edge of the helm.
Mark the holes on the helm (if they don't already exist) with a marker.
Step 2: Fastening Technique
Method A: Rivets (Durable and Historical)
This is the most commonly used method for a permanent inlay.
Punch holes: Use a leather punch to make holes in the leather band of your inlay.
Align: Place the inlay in the helm and make sure the holes in the leather are aligned with the holes in the steel.
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Rivet: Use solid rivets with washers (as discussed in our previous guide).
Tip: Place the washer on the inside (against your head) and make sure the rivet is inserted from the outside. Use rivets with a flat head on the outside for a sleek appearance.
Method B: Screwed Inlay (Replaceable)
Handy if you want to be able to wash or replace the inlay.
Use bolts: Use short M3 or M4 bolts with a rounded or countersunk head on the outside.
Secure: Use a lock nut on the inside or a drop of thread-locking compound (Loctite) on the thread. This prevents the bolts from loosening due to vibrations while wearing.
3. Important comfort tips
The 'Floating' Fit: Make sure the lining keeps the helm at a distance from your head. If your helm fits too tight, add some extra padding (such as wool felt or foam rubber behind the leather).
Protect edges: If you use rivets, make sure they're covered on the inside (where your head sits) by the flap of the inlay. If a rivet is still exposed, tape it with a piece of soft leather to prevent chafing.
4. Workshop Checklist
[ ] Solid rivets and washers (or bolt set).
[ ] Leather punch (for making holes in the lining).
[ ] Ball hammer and rivet setter.
[ ] Wool felt or soft leather (for extra padding/cushioning).
Expert tip: If your helm "tilts" while moving, the inlay is often positioned too high or the fit isn't even all around. A perfectly fitting helm should stay stable without a chin strap, purely through the friction and fit of the inlay. If that's not the case, your inlay is probably too small or not properly centered.
