The Illinois Fighting Illini football team has unveiled a stunning new uniform that pays homage to its rich history. A standout feature of this new look is the meticulously crafted helmet, designed to replicate the appearance of classic leather headgear. To achieve this unique aesthetic, the university collaborated with Armando Villarreal, a specialized airbrush artist from southern Nebraska. Villarreal, one of only two experts in the country with this niche skill, is hand-painting each helmet to ensure an authentic vintage feel.
The creation process is intricate and time-consuming. Each helmet undergoes a careful sanding to prepare the surface, followed by a sealant application. Villarreal then applies a base coat and allows it to dry before lightly scuffing the surface to create a subtle texture, mimicking the grain of leather.
Next, a dark brown coat is sprayed onto the helmets. Villarreal employs stencils to enhance the leather-like effect, adding visual depth and realism. Once this layer is dry, he masterfully airbrushes details such as straps, stitching, and ventilation holes, all contributing to the faithful recreation of helmets from the 1924 era, famously associated with the legendary Red Grange and his Illini teammates.
To finalize the transformation, Villarreal applies a clear matte coat. Each of these distinctive leather-brown helmets, subtly different in shade from the jersey’s tan due to variations in 1920s leather, requires between one and two hours of dedicated hand-painting. Bret Rosch, the team’s representative involved in the uniform project, emphasized that this level of detail was essential to capture the precise vintage look the team envisioned.
“A century ago, jersey designs were largely uniform, so we recognized that the leather helmet aesthetic would be a key differentiator,” Rosch explained. “To truly stand out, we needed to recreate that textured leather helmet look. The helmets of that period featured straps forming a distinctive sun pattern on top, and hand-painting was the only way to accurately replicate this. We aimed to mirror every individual piece of leather from the original helmets onto the modern shell, making it appear as though the players are genuinely wearing those vintage helmets.”
Rosch lauded Villarreal’s artistry and collaborative spirit throughout the project, stating, “Armando has done an exceptional job and has been an invaluable partner in this entire process.”
The comprehensive uniform design initiative commenced nearly two years prior to its unveiling. Following six to eight months of conceptualization and initial design development, the Illini team worked closely with Nike to refine and finalize the uniform’s overall appearance. Conference approvals were then secured, setting the project in motion for production.
Athletic Director Josh Whitman’s involvement was pivotal throughout the design journey. His dual perspective as both an administrator and a former Illinois football player brought unique insight to the creative process.
“Josh possesses a special connection to this project due to its personal resonance,” Rosch commented. “We meticulously refined numerous details to ensure the final design aligned with his vision and effectively captured the historical essence we aimed to embody.”
