I made this Homemade Fire Chief Helmet Cake to celebrate the birthday of the fire chief in our community.
I started by tracing an actual helmet (my son is a volunteer fire fighter) onto poster board. I then traced the poster board shape onto flexible cardboard. I glued the two pieces together and curved it. I held it in place by stretching a piece of package tape from one side to the other. I allowed that to dry over night. I baked two 9" round cakes and then used 1/2 of another cake I mixed and baked it in a Pyrex mixing bowl.
After allowing them to cool I layered them with butter cream, crumb coated the entire cake and allowed it to dry overnight. I used a fondant recipe that called for 1 lb of miniature marshmallows melted in the microwave and then mixed and kneaded with 2 lbs of powdered sugar. I covered the cardboard brim with white fondant and placed the cake on top. I rolled fondant into ropes and put them over the helmet to make the raised areas and then covered the entire top with fondant. I made a 3/4" strip to put along the base of the cake where it the fondants met. The shield was a piece of cardboard also covered in fondant. I piped the letters on and allowed it to dry flat over night. My son also had an extra eagle shield holder so I applied that and secured it with toothpicks.
I placed the entire cake onto a piece of floral foam I covered with aluminum foil and used tacky glue to hold it on a 1/4" piece of wood cut to size and covered with freezer paper. I wrapped fondant around the foam to hide it. The rear of the hat was made to look like the fireproof hood they wear. I hear it was a big hit.