Custom Steel
Firefighter Helmets.
Built by Hand.
Our decorative steel helmets are the perfect legacy piece for any firefighter. They are individually fabricated, welded, and assembled by Dan using locally sourced American steel and completed with brass finishes.
- Handcrafted in the USA
- Firefighter & Veteran Owned
- Built to Order
I'm Dan.
My love for building and creating with metal started young. I began working for an HVAC company at 14 years old, which sparked my interest in metal fabrication. After serving in the Army for 8 years, I joined Boston’s Sheet Metal Workers Local 17 and worked with metal for years, honing my knowledge and skills. Eventually I got on the Boston Fire Department, and these days you can find me either in the firehouse or my favorite place, my garage, meticulously crafting, welding, grinding, and fabricating unique creations from all sorts of metal.
The inspiration for the custom firefighter helmets came after I made a steel replica of a friend's spare helmet. The metal used to build the very first helmet was made of throw away 3/8ths scrap collected off of fire watch details and the side of a metal file cabinet. I left that helmet on the workbench in the firehouse and, even though it was just a rough prototype, people were drawn to it - asking if I could make them one.
The positive response from those who saw it and wanted one helped me recognize the need for a unique and meaningful firefighter legacy piece. Since that first helmet, I’ve been hard at work in my garage refining the process, style, and look so that I can proudly offer a custom creation that not only lasts a lifetime, but holds meaning for the generations to come.
Here at Torched Steel, it’s just two of us. I spend weeks creating each unique helmet in my spare time, and my wife Bridget helps manage the business after working her own 9-to-5.
The Work
A look at some of the custom helmets I've put together. Every one is different, because every firefighter's story is different.
Every Helmet. Built From Scratch.
These aren't mass-produced decorations sitting on a shelf in a factory somewhere. Each helmet is a full-scale replica that I cut, shape, weld, and assemble by hand from American steel.
Full-Scale Steel
The same size as the helmet you wear into jobs. Just a few pounds heavier.
Custom Engravings
Your name, badge number, company, station, years of service, department, logos, portraits. Whatever tells your story. Each helmet is personalized to the firefighter it’s honoring.
Brass Finishes
Eagles, front pieces, and hardware finished in brass, the same ones that go on your real lids.
DiamondFinish Clear Coat
A professional clear coat so the finish holds up for years, whether in a firehouse, a living room, or a memorial hall.
You tell me what you want on it. I build it. That's it.
A Piece Worth Keeping
Retirement Gifts
20, 25, 30 years on the job. A plaque is nice. A full-scale steel replica with their name, badge, and years engraved on it? That's something they keep forever.
Memorials
For the brothers and sisters we've lost. A steel helmet built in their honor, with their details engraved into it, so they're never forgotten.
Firehouse Displays
Put one in the house with the company name, station number, and district. Something the whole crew can be proud of.
Anyone Who Loves the Job
You don't need a reason. If you or someone in your life lives and breathes the fire service, this is the gift that hits different.
From the Firehouse
The fire helmet created for me by Torched Steel is by far the best gift I received on the occasion of my retirement. The craftsmanship, the attention to detail, and the inscriptions are perfect, personalized and have a beautiful appearance. Dan is one of kind, his work is exceptional and I will cherish this helmet for the rest of my life. I would recommend Torched Steel to anyone looking for a perfect product that will last a lifetime.
Friend, your talent is something to be proud of. Chief walked in this am, a very humble man, he opened it and was immediately grinning from ear to ear and even tried it on. He is very impressed with this gifted artwork. We really appreciate what you have crafted. All are speechless of the product. And yes the box was kicked like a new recruit in the galley, but the helmet was flawless.
I was totally surprised when my sons gave me this precious helmet! All my friends and family got to see this work of art, and everyone loved it! I too worked in sheet metal so I can appreciate the work that goes into fabricating something of this nature. I'm very appreciative of the work you've put into this piece of art, and I'll probably pass it down to my grandson some day!
Brother, Just got home from shift and opened the helmet. It looks even better in person! Your craftsmanship is amazing. Thank you so much, we’re excited to give it to him.
Dan, received the helmet two days ago. Still amazed how you take metal and make it look so good… I can’t say enough about your craftsmanship.
You are the motherfucking man… this helmet is absolutely breathtaking… I will never be able to thank you enough.
Pictures didn’t do it justice whatsoever. The helmet looks amazing. You do dang good work sir and he will be honored to show everyone that helmet. Thank you again for the quick build time and getting it finished in time. You sir are the real hero in this and my brother and I can’t thank you enough for it.
Four Steps. No Surprises.
Start Your Request
The best way to start is the order request form so all your details are in one place. Not sure exactly what you want yet? Text, email, or DM me and we'll figure it out together.
We Confirm Details
I'll reach out to you via email to confirm the order, delivery date, and any custom engravings requested.
I Build It
I get to work in the shop. Each helmet takes about 4–6 weeks and I'll reach out when it's ready to ship. If you want a sneak peek before it's boxed up, just let me know.
You Get It
Once it's done, I pack it up and send it on its way. Payment isn't due until the helmet is packed and ready to go.
What It Costs.
A full-scale, hand-built steel firefighter helmet ready to display, including your choice of front holder, a shield with your number and/or text, and your name on the brim.
- Add custom images to side panels, the shield, or under brim $30–$60 ea
- Add additional text or quotes $20–$30 ea
- Typical build time 4–6 weeks
you don’t pay until its done and ready to ship.
You're paying for real steel, real craftsmanship, and a one-of-a-kind piece, not something stamped out of a machine, printed by a 3D printer, or poured into a mold. And we don't collect a dime until it's ready to ship.
A portion of every helmet goes to the Boston Firefighters Burn Foundation, supporting firefighters and burn survivors.
Good to Know
How long will it take to receive my order?
What happens after I fill out the Order Request Form?
What forms of payment do you accept?
Where do you ship?
Will the helmet rust?
Every Helmet Has a Story.
Want to honor someone? Just want one for yourself? The easiest way to start is to fill out the order request form with who it's for and what you're thinking. Have questions first? Reach out anytime. I'm easy to get ahold of.
A portion of every sale goes to The Burn Foundation.