Tape the Velostat to the sides of the helmet last, after you check that the helmet fits and the Velostat is as flush to the interior as you can make it.
Use lots of tape to make the helmet. You will sleep in it and wear it as much as you can.

When all 8 sheets are cut and taped to the inside of the hat, test the hat for fit before final taping.

Secure the Velostat to the hat with strips of tape.


  1. Tape the Velostat sheets securely to the hat with strips of tape all the way around.

  2. Tape the sides of the hat last by holding the hat taut with one hand and applying tape strips with the other hand.