Bike Helmets for Unusual Head Shapes
Summary: Although nobody makes custom helmets, here are some ideas for making a standard helmet fit your unusual head shape.
Riders with unusual head shapes often find it difficult to find a bike helmet that fits.
As far as we know, nobody makes a custom bicycle helmet. It would be prohibitively expensive to design one, make the molds, produce enough samples and have it certified by a test lab to the legally-required CPSC standard. With administrative and other overhead costs a manufacturer would have to budget $25,000 or more to produce the one helmet.
The best advice we can offer is to get a larger helmet and add fitting pads where needed. You would need enough padding to be sure that the helmet is stable on your head so that it is in place when you crash. We have a page up on larger helmets.
You may have better luck with one of the one-size-fits-all helmets, with what we call ring fit. They are sized with a band around the head rather than fitting pads.That might work out better for your head shape, but since the helmet will probably be larger than you would normally require, you may need to glue in pads to be sure it will be stable on your head.
Denting or shaving down the inside of the stiff foam liner to make the helmet fit you would reduce your protection, so that would not be an optimal choice.
You might want to start with one of the helmets that has extra rear coverage, since those are inherently more stable on your head. We identified some of those in this section of our review of helmets for 2013.
Depending on your head shape, it might help to start with a rounder helmet that fits Asian heads. That might give you more room where you need it, depending on your head shape. If so, take a look at our page for rounder heads.
We are looking for a custom helmet manufacturer, and will update this page if we find one!
This page was updated or partially revised on: October 1, 2016.