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Among the key suppliers in the Formula 1 paddock, those who supply drivers’ helmets are among the least visible, yet the most important, going so far as to influence a driver’s performance and result.
Motors Inside was able to visit Bell, at the headquarters of Racing Force Group, near the Bahrain circuit. The group welcomes the companies OMP (belts and gloves), ZN (Zero Noise), which takes care of intercom radio communications or the miniature camera used for F1 broadcasts, as well as Racing Spirit (clothing).
The Belgian brand, Bell, has been located in Bahrain for several years, while the island has now hosted Formula 1 for 20 years now. The Sakhir factory can build all sizes of so-called standard carbon helmets, as well as custom helmets for F1 drivers.
Bell is not the only helmet manufacturer that meets FIA safety standards (CIK). In addition to the standards to be respected, some manufacturers undertake to provide even greater resistance, particularly for flame resistance.
In addition to full helmets, such as those of F1 drivers, Bell also manufactures helmets for rally drivers and motorcycle racers. The helmets are manufactured for the major FIA series but also for amateur drivers who wish to obtain safety standards for driving on circuits from time to time.
But these are not the only helmets made in Sakhir. Mini helmets, or replica helmets, are also made here. They are used in particular for team marketing or even offered during events organized by the teams.
The hundred or so Bell employees are divided into several areas: the construction of the carbon hull, the installation of the interior foams and safety elements, as well as the painting.
Read: How Formula 1 helmets are made
“Whether in Formula 4, Formula 3 and even Formula 2, most have helmets with standard external sizes, unless someone is followed by an F1 team, like Mercedes, Alpine or Ferrari and in which case we can make them a helmet with custom 3D scanning »Michael Aumento explained to us. “We have a contract for 12 and 15 helmets per year. For one Grand Prix weekend alone, we prepare 4 helmets. Two for rain and two for dry, depending on the air intakes and visors. »
In F1 alone, therefore, with the dozen drivers managed by Michael’s team, the factory must produce 200 custom-made and painted helmets per season.
Read: The secrets of F1 helmets
Custom paintings
Each season has its share of glamorous, historic and special Grand Prix. Whether it’s a home circuit or a classic event on the calendar, drivers all have a good reason to create specific designs. Thus, for several years now, the business of special paints has grown more and more. Bell, to maintain the production of custom helmets, hired around ten painters to do custom paintings.
“Here in Bahrain, we have 9 people in the paint workshop and in Belgium, we have the Racing department with three dedicated painters. » Note that several pilots have their own painters, with whom Bell collaborates by sending them helmets without any decoration.
In addition to the design, this makes it possible to best adjust the quantity of paint on the helmets to optimize their weight. “All the regular drivers we have, we have always painted their helmets. By doing it ourselves, we also manage the weight of the paint. A helmet with 50g more paint changes a lot, with the G and in the event of an impact. »
Also note that the helmets are some equipped with a mini-camera for live broadcast on TV, a camera produced by ZN, one of the brands of the Racing Force group.
An exhibition hall full of history
The Bell exhibition hall is salivating. The helmets of Niki Lauda, James Hunt, Alain Prost, Ayrton Senna and even that of Romain Grosjean after his terrible crash in Bahrain are on display.
In addition to helmets, Bell also keeps some miniature Formula 1 cars as well as parts, such as this Lotus Renault spoiler.
Mini headsets, a recent business
Mini helmets have been the new fashionable items for several years. Easier to store at home and cheaper than a 1:1 replica helmet, the mini helmets of pilots affiliated with Bell are manufactured directly here in Sakhir. Depending on the needs of the team, they can be produced in very large or even very small quantities. They are just as functional as a 1:1 helmet, produced in carbon, with the same foam inside and the same visor, but unless you have the face of a cat, you will only be able to use them on your shelf.
Each series produced is painted on the production line then improved by a painter to refine the details and apply the stickers.
A mini helmet can be sold between €150 and €450 depending on its rarity and decor.
