The reproduction of Philip II's kabuto is the result of a complex process based on studying the historical records of the collection and creating a 3D model. This process provided very valuable information about the standard of craftsmanship of sixteenth-century Japanese artisans, as well as key indications on how to reconstruct areas that are no longer visible.
In 1849 the kabuto was described as resembling ‘a shaven head’, with a red lacquered surface, two eyes depicted on the visor and ‘a large bristle tuft’ on the nape of the neck. This description is compatible with the use in some Japanese armour of yak or horse hair, though it differs from the appearance of sealskin referred to by Philip II's armourers who compiled the inventory. All this is consistent with the photographs taken around 1860 by Jean Laurent. However, the 1838 drawing is different in that the crest of the kabuto does not appear to be shaven but has a certain volume. Actually, as was found during the reconstruction process, this would have been an optical illusion caused by the considerable height of the crown of the kabuto, whose tautly pulled hair looks like a crest when viewed from the side, even though in reality it is not.
Given the discrepancies between inventories, it was decided to use horsehair for the crown of the kabuto, undoubtedly the most hypothetical aspect of its reconstruction, although it could have been made of yak hair, pulled taut in the manner of the traditional Japanese hairstyle. This choice was also aesthetically and constructionally coherent with the crest or tuft that surmounted it according to the side view in the 1838 drawing and the presence of animal bristle or hair noted in 1849. This treatment does not seem incompatible with its definition as a shaven head, as suggested by the frontal view in Jean Laurent’s photographs and the remains of possible degraded hairs that can be seen in it.
The 3D model of the original was constructed after taking hundreds of photographs of the object from multiple angles. And its materialisation consisted of a 3D metal print made by selective laser sintering (SLS) of stainless-steel powder. All subsequent work was based on historical sources, employing a completely artisanal process similar to that of its original creators.