How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
I think this is the biggest project Iíve done yet. My favourite movie is the Iron Man and I wanted to get an Iron Man helmet, but Iím a student and I couldnít afford it. Then I decided to make one. Now Iíve done and I really like this helmet. Iím happy that I didnít buy one.

Step 1: Safety

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
You are going to work with dangerous materials. Always wear respirator while you are working with resin or you are sanding. Resin isn't good to touch before drying, so it's recommended to use rubbergloves too.

Step 2: What will you need

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
What will you need:
-17 hard papers (I used 210gsm paper. (gsm = gramms per square meter). I tried 250gsm paper too, but it was too hard and it couldn't suck the resin in.
-Technokol Universal glue
-Polyester resin
-fiberglass cloth
-resin based filler
-metallic gold spray paint
-rally red spray paint
-sand papers (60, 120, 360)
-6 LEDs
-a small switch
-2 batteries
-a battery holder
-wires
-soldering wire
-electrical tape
-a piece of transparent plastic (for the eyes)
-two pieces of wood (10cmx2,5cm)
-small magnets

The tools:
-hot glue gun
-soldering iron
-scalpel or scissors
-engraver (isn't necessary)

Warning!
Always wear respirator while you are working with resin, paint or you are sanding! Fumes and dust can damage you lung, if you are not careful enough.

Step 3: Printing and cutting the parts

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
The mask has a paper base, which is designed by a program named Pepakura. It makes 2D parts from a 3D model. Fortunately, you donít have to design the model, here is the .pdf file. You have to print them to hard paper. Normal paper doesnít work perfectly.
After you have printed you have to cut the staight lines out (donít cut the interrupted lines). You can use scissors or scalpel.
If someone knows how to use pepakura here is a link where you can download the pdo file: http://www.4shared.com/file/Kd2YFv88/IronmanA4.htm
How to make a lifesize, wearable Iron Man helmet
Iron Man a4 (1).pdf229 KB

Step 4: Gluing the parts together

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
You can use almost any kind of glue you want. I tried glues and the Technokol Rapid universal glue worked the best for me. It dries fast, so you donít have to wait much.
As you can see there are two of every numbers ont the parts. Every number goes to the same number. It helps you to match the parts together.
The helmet will have a drop down back, so donít glue it to the front part.
There are two triangular parts. You need those parts until you resin the helmet. They hold the two sides close until the helmet hardens. After that you don't need them. You can see on the pictures where you should put them.

Step 5: Resin and fiberglass

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
The polyester resin and the fiberglass makes the helmet strong and durable. The first layer should be only resin ont he outside of the helmet. The next layer should be resin with fiberglass in the inside. Then add two or three more layers of fiberglass with resin to the inside.

Step 6: Filling and sanding

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
I used Trinat filler, which is a one component, resin based filler. I added about 3 layers and sanded after each layer. The numbers of the sandpapers I used were 60,120 and 360. I This step takes longest time, so be patient.

Step 7: Painting

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
I used masking tape to cover the places I don't want to paint. The paint sprays I used were a metallic gold and a rally red. I painted two layers.
It is highly recommended to paint the inside too, so you don't have to inhale the resin.

Step 8: Making the back part

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
The method is the same: Resin, fiberglass, fill, sand, paint. In the real Iron Man helmet the ears are not just a simple circle, but on the paper base they are. I made the original ears from a 3mm thick wood plate and glued a piece of plastic to the bottom of them. After that I glued the ears in place.
You can't put your head inside until you have removed the back part, so you'd better use magnest to make it removable.

Step 9: Making the teeth and the eyes

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
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The teeth are two piece of wood (10cmx2.5cm) with thease engraved lines. I painted them black and glued inside the helmet using hot glue.
The eyes are LEDs behind scrached transparent plastic (you can get it from for example plastic cups). You can scarth the plastic using sand paper. Then you should glue the LEDs using hot glue. After that, you have to add a piece of aluminium foil or beer can to reflect the lights. Don't forget to leave a few milimeters under the eye lights, so you can see trough.

Step 10: Wearing :)

How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
How to make a lifesize, wearable Iron Man helmet
Congratulation! You have finished your own Iron Man helmet! :)
I hope you enjoyed this tutorial as I did making it.
If you have any questions leave a comment or send me a message.
 
 

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