T-65 Power Armor Helmet Kit (Unassembled) Fallout 76 DIY Cosplay | Thermoformed ABS Shell + Lens + Tubing + Foam

- T-65 Power Armor Helmet Kit – Fallout 76 DIY Cosplay Build (Unassembled)
Forge your place among the Brotherhood with this life-sized, unassembled T-65 Power Armor helmet kit, inspired by Fallout 76. Thermoformed from durable, textured 1mm black ABS plastic, this helmet is scaled to the iconic Mechsuit dimensions and built for cosplayers, collectors, and DIY survivors of the post-nuclear world.

Whether you’re gearing up for a convention, Wasteland LARP, or a killer build display, this helmet is lightweight, breathable, and ready to be fully customized.

⚠️ PLEASE NOTE: This is a raw, unpainted, and unassembled cosplay helmet kit. Buyer assembly and adjustments may be required.

What’s Included:
(1) Left & Right Helmet Shells (Thermoformed black textured ABS – 1mm thick)

(2) EVA Foam Seam Strips (for internal connection at shell seams)

(1) Reflective Mirror Lens (Ready-to-install)

(1) Corrugated Tubing (for exterior helmet detailing)

❌ What’s NOT Included:
Paint or weathering materials

Electronics, padding, or internal components

Helmet display stand or other armor parts
- - -Assembled helmets shown in listing photos are for reference only. - - -

🛠 Assembly Instructions & Fit Details:
This helmet comes in two parts (left & right shells) and is assembled by:

Applying contact cement or hot glue to an EVA foam strip

Affixing the strip to the edge of one shell

Allowing it to overlap, then aligning and attaching the second shell

Sealing visible seams with Dab ElastoPatch or PlastiDip spray (optional for smooth finish)

Sizing:
• Designed to fit most head sizes (~23–24" brow diameter)
• If needed, buyers can increase spacing with foam or trim base edges for more room
• Interior is compatible with aftermarket fans, audio, or light systems (not included)

Pro tip: For comfort, add your own memory foam or helmet padding to the interior with spray adhesive for a snug fit.

💬 Fallout Collaboration & Community Shoutouts:
Looking to 3D print instead? Shoutout to AppalachianForgery for the STL file version of this helmet – check it out here:
AppalachianForgery on Etsy

Need build tips or visual help?
Visit me on Instagram: @dead_exposuredf for cosplay tutorials, build guides, and Ranger-ready inspiration!

💡 Perfect For:
Fallout 76 & Brotherhood of Steel fans

DIY cosplay and prop builders

Post-apocalyptic con-goers and LARPers

Collectors seeking modular wearable props

💬 Questions?
Message me any time! I’m happy to help with custom sizing tips, commissions, or full suit builds. Want a paintball/airsoft-ready version? Ask me — I’ve got options.