By James Heinz
When we got done with the helmet, it looked like Darth Vader’s burnt and crumpled helmet in one of the recent Star Wars movies. It was actually a classic Morse diving helmet from the 1900s. As I reported in a previous blog post, I have dived in this classic equipment. In February, I attended a classic diving helmet repair seminar at the DESCO Diving Equipment Company in New Berlin, Wis. Below is a series of photos showing how the wizards at DESCO took the battered relic apart in order to bring it back to life. (Story was originally posted Sep 26, 2024)
INITIAL DISASSEMBLY OF THE HELMET BEGINS
Photo at top of page: ONE OF THE VIEWING PORTS IS REMOVED
INITIAL DISASSEMBLY IS COMPLETE:
THE EXHAUST VALVE IS TAKEN APART:
REVEALING A SPIDER WEB IN THE EXHAUST VALVE:
ONE OF THE FIXED VIEWPORTS IS REMOVED FROM THE SIDE OF THE HELMET:
THE VIEWPORT WAS SEALED WITH RED LEAD:
ONE OF THE VIEWPORT FRAMES IS REMOVED FROM THE HELMET:
THE EXHAUST VALVE IS REMOVED FROM THE SIDE OF THE HELMET:
THE HELMET AFTER COMPLETE DISASSEMBLY:
THE INSIDE OF THE HELMET AFTER FINAL DISASSEMBLY:
THE PARTS ARE SANDBLASTED CLEAN:
THE PARTS OF THE HELMET AFTER BEING SAND BLASTED:
THE BREASTPLATE IS EXAMINED:
A CRACK IS DISCOVERED IN THE BREASTPLATE AROUND ONE OF THE BOLTS:
THE BREASTPLATE IS HEATED SO THE BOLT CAN BE POUNDED OUT WITH THE HAMMER:
THESE FORMS WILL BE USED TO CONSTRUCT A NEW BREASTPLATE:
DESCO OWNER CHRISTIAN KOELLNER POSITIONS A SHEET OF COPPER FROM WHICH A NEW BREASTPLATE WILL BE CONSTRUCTED:
THE SHEET OF COPPER IS HEATED TO FORM A NEW BREASTPLATE:
THE NEW BREASTPLATE IS SHAPED BY POUNDING THE HEATED SHEET OF COPPER ON ONE OF THE FORMS:
A NEW BREASTPLATE HAS BEEN CONSTRUCTED:
I had to leave for another appointment and was unable to document the entire process. The only way to see how something was made is by taking it apart, and it was fascinating and informative to see how this classic dive helmet was built.
The helmet was put back together at the next Lake Michigan Classic Diving Organization meeting on Saturday September 9, 2024.
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James Heinz is the Wisconsin Marine Historical Society’s acquisitions director. He became interested in maritime history as a kid watching Jacques Cousteau’s adventures on TV. He was a Great Lakes wreck diver until three episodes of the bends forced him to retire from diving. He was a University of Wisconsin – Milwaukee police officer for thirty years. He regularly flies either a Cessna 152 or 172.
Photos by James Heinz.
