Step 1: Safety
Step 2: 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
-resin based filler
-metallic gold spray paint
-rally red spray paint
-sand papers (60, 120, 360)
-a small switch
-a battery holder
-a piece of transparent plastic (for the eyes)
-two pieces of wood (10cmx2,5cm)
-hot glue gun
-scalpel or scissors
-engraver (isn't necessary)
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
After you have printed you have to cut the staight lines out (don’t 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
Step 4: Gluing the parts together
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 don’t 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
Step 6: Filling and sanding
Step 7: Painting
It is highly recommended to paint the inside too, so you don't have to inhale the resin.
Step 8: Making the back part
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
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.