Always stuck on the idea of modeling the appearance of a leather helmet, the Illini reached out to their vendors to find a solution, which came via Armando Villarreal, the owner of an airbrushing company in southern Nebraska, who will hand-paint each individual helmet. Villarreal is one of only two artists in the nation who specialize in airbrushing football helmets.
The process is quite complex. The helmets are first sanded down before being sprayed with a sealer. Villarreal then adds a base coat before letting the helmets dry and scuffing them up a bit to add some texture.
The helmets are next sprayed dark brown, and Villarreal uses a stencil to give the exterior a more authentic leather look. Once the helmets dry, Villarreal airbrushes the straps, stitching, and holes, all of which help replicate the look of the helmets worn by Grange and the Illini in 1924.
Villarreal completes the helmets by adding a clear coat to create a matte finish. Each of the leather-brown helmets – which are a slightly different shade from the tan color of the jersey due to the kind of leather that was used during the 1920s – takes one to two hours to complete, but Rosch knew he needed that level of attention to detail to achieve the team’s desired look.
“100 years ago, the jerseys all had very similar designs, so we knew what would set us apart in that overall aesthetic was a leather helmet and to create that textured look,” Rosch said. “On the helmet, there are straps that go over the top and form a sun pattern, but the only way to accomplish that was for it to be hand-painted. For each individual piece of leather that was on a leather helmet, we wanted it to be reflected on the shell of the helmet so it looked like you were wearing that helmet.
“Armando has done a really great job and been a really good partner in this whole process.”
The entire uniform design process started nearly two years ago. After spending roughly six to eight months developing the concepts and creating the initial designs, the Illini worked heavily with Nike to settle on the final look. Once the team received conference approval, the ball really got rolling.
Director of Athletics Josh Whitman played a key role in the entire process, and his experience as both an administrator and an alum of the football program shaped the way the team went about creating the final design.
“He has a little extra tie to the project as a whole because it represents something really personal to him,” Rosch said. “We tweaked a lot of small things to make sure everything fell in line with his vision and how we think we can tie that together.”