It All Starts With A Shell...
It all starts with carbon fiber shells. For AGV, the shells are outsourced, molded by a third party before being delivered to the Movena plant for assembly.
This is what a helmet looks like devoid of all its components.
The Good Old Tape Trick
Even future helmet need some taping before a paint job. The carbon fiber lids are sanded down by hand before masks and tape are applied to cover certain areas of the shell that will receive a different treatment.
For instance, in the case of the Valentino Rossi 2019 Winter Test design, the chin of the lid needs to remain black, while the rest is painted bright yellow.
Bake In The Oven For 40 Minutes
Once all the sections of the motif have been applied, the shells spend 40 minutes in an oven to set the graphics.
After cooling down, the protective film on top of the graphics is peeled by hand before the lids are given a thorough wash.
Time For The Protectors To Go In
The next step involves inserting each pieces of EPS foam shell into the lid and gluing them into place by hand. Each piece of high-density foam has its own homologation tag to ensure its quality.
Clamps are used to hold the styrofoam into place while the glue dries.
All The Tags!
This is also the step at which the helmet receives all its stickers and tags, once it passes QC of course.
Ready To Hit The Shelves
Each helmet is identified with a barcode which allows workers to follow its progress through the assembly process. At this point, the quality control technician scans the helmet one last time and weighs it to ensure it meets the standards.
The helmets are then placed in their pouch and packed in boxes, ready to be shipped out to future customers.
This special edition AGV Pista GP R 2019 Winter Test edition retails for about €1,500 ($1,700).