Inside The Made To Order Process For A Handcrafted Helmet

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.

For a full sizing guide across our range, visit leather trimmed helmet range.

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.

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.

The liner deserves the same care. A removable, washable liner keeps the inside fresh, and following the maker's washing instructions protects both the padding and the stitching around it.

A helmet workshop in London works on a smaller scale than a mass production line, and that shapes almost everything about how a helmet gets made. Materials are chosen and checked by hand, shells are shaped and finished in small batches, and problems are caught by people who see every stage, not just a sensor on a line.