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How it’s made: Kimi’s racing helmet

Along with its owner, we went to discover how Kimi’s helmet was born, in the factory that Bell Helmets Racing has built a few meters from the entrance of the Al Sakhir circuit, in Bahrain.

The parts of pre-impregnated carbon fiber are cut into specific shapes before being placed in a shell mould.
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Up to 40 pieces of carbon fibre are positioned very precisely in a female mould. This is called the “lamination” of the shell.
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When lamination is completed, the shell goes into an oven at 150 °C under vacuum for 30 minutes. This is a shell coming out of the oven.
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The opening for the visor, called the eyeport, and the excess of carbon in the lower part of the shell are cut with a jig saw.
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Now the shell already looks like a real helmet… The technician will now position the shell in a jig, allowing him to precisely trim the 12 ventilation holes on the helmet.
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To obtain homologation, the helmet must pass a series of tests including penetration. This test consists of a spike weighing 4kg being fired into the helmet at a speed of 10 meters per second. Bell uses a special machine for this kind of test, developed and built in-house.
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The shell is being prepared for painting by being carefully hand sanded…
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The shell receives a thin and smooth layer of clear coat, before being personalized into Kimi’s design.
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The interior parts are now fitted inside the painted shell.
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Finally, the transparent aerodynamic spoilers and the air intakes are glued onto the helmet, and here we are…
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…ready to go!
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Video: watch how it’s made!

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