Picture of How to make a lifesize, wearable Iron Man helmet
I think this is the biggest project I’ve done yet. My favourite movie is the Iron Man and I wanted to get an Iron Man helmet, but I’m a student and I couldn’t afford it. Then I decided to make one. Now I’ve done and I really like this helmet. I’m happy that I didn’t buy one.

Step 1: Safety

Picture of Safety
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.
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jdt255132 days ago
Hello, i have never made a helmet like this but i am a big fan of Ironman. Is there anyway you could post the step by step directions to putting the pieces together? Or just email me the steps?
MarieA1316 days ago

you're amazing!! cooool!!!!

Bobgeo1 month ago
I am half way done and now I Started getting problem the ear pice is not properly attaching to the flat piece as it is too short I have printed everything in a4 paper and still face this issue, the piece frome the page 11 is not going with the page 1 here is the image please help
Nice! Do you know how I could get the mask to open up? And how much did this helmet cost overall?

I think in this particular design there isn't a way to open up the mask, but you could look for a tutorial on youtube (there are a lot of those tutorials) and you could adjust your helmet Good luck!

MridulA12 months ago

Hi there! Nice work with the helmet! :)
I've printed the pdf which you've provided to make on too but I'm facing size issues with my cuttings. I've printed and cut the exact pdf. It is exist some parts only. Here is a pic of the same. Please tell me if I've done something wrong or It's a fault in pdf. :(

Same problem here.
Don't know what is wrong.

I didn't had that problem, but maybe you printed not al the pages at once? that the printer resized some of the pages to match te paper? at least my printer resized the pdf to fit the paper.... Currently I'm starting al over again, I tested a lot of materials end methods. Now I'm using a model from internet (that i had to open wit pepakure viewer) I'm currently printing all the pages (I guess around 150 pages at least)

MridulA12 months ago
MattL62 months ago
I'm just starting out on it and even on the first one it seems way too small... I printed it directly from the PDF. Will everything work out?
geq1 (author)  MattL62 months ago
The pdf was designed for a4 paper. If you printed it to a4 it should be the right size.

Hi Can you tell me the dimensions of this helmet. Is there any guidelines on how to scale up the size of the helmet. Really appreciate any help you can give. Thanks.

geq1 (author)  robert.bradley.564813 months ago

About 25x18x22 in centimeters.

nikola.kucar11 months ago

Do you have pep file?

geq1 (author)  nikola.kucar3 months ago

Yes, the link is in step 3.

A good job, I'm impressed

geq1 (author)  BartłomiejH3 months ago


ok first of all. awesome. second. i used the file.but when i made it. it was too small. i made it bigger. but still. its too small

geq1 (author)  baron.ren.73 months ago

Which one did you use the pdf or the pdo?

How would you put the parts together, are there numbers that correspond with each other?

geq1 (author)  CaptainRex21213 months ago

Yes, every number goes to the same number.

afriyann7 months ago

Can you give me the video tutorials in order to practice, in order to more clearly
I come from Indonesia

geq1 (author)  afriyann3 months ago

There are tutorials on youtube from other people.

timojloo7 months ago

The finished product is excellent! I'm part way though making my own and I have a few questions:

1. Did you glue the faceplate in place before applying resin?

2. It looks like you applied resin to the whole helmet at once - how did you keep the back piece attached?

3. Is there a gap at the back between the back piece and the helmet?

Any feedback would be highly appreciated! Keep up the good work :)

geq1 (author)  timojloo3 months ago

1. Yes, I did.

2. I used duct tape.

3. Yes there is a small gap. It's necessary for the hinges.

If there are more questions, I'm happy to answer them. :)

simong1133 made it!4 months ago

This was a lot of fun to make. It was my first time making any kind of helmet / prop replica, or working with fibreglass, pepakura or fillers, so I made quite a few mistakes along the way. But I can't wait to try again and get better at it. Thanks for the brilliant guide.

geq1 (author)  simong11333 months ago

Your welcome. Nice prop.

EricVera5393 months ago

Hi! thanks for all the step by step info. I have a simple question.... can I do this whole thing using normal paper instead of hard paper? I just can't find it in any store. /: What would happen if I go with normal paper? thanks for the post.

geq1 (author)  EricVera5393 months ago

Unfortunatelly, no. Maybe with simpler models, but not with this. You can order from ebay too.

I researched the exact same thing you are having trouble on and found that cardstock paper works well based off other models I've seen.

This is one model I'm talking about => http://visualspicer.com/personal-work/r2-a4-star-...

As well this one => http://visualspicer.com/personal-work/starfighter-...

Both are a PDO and PDF file that follows the same printing process and both used Cardstock Paper.

Hope this helped!

teena.tobey3 months ago

Cool Version of the helmet


Cool Version of the helmet


hshahzad16 months ago
can you give the video please

how much time you took to finish this helmet ?

I printed it out last week and just finished it today. Only working on it a couple hours a day though.

j-vega1 year ago

Ten out of ten !!!!! ;-)

fcolon21 year ago

could you please share the .PDO file with me as well? ferdinandcolon41@gmail.com

Can you please show me or have a tutorial on how to cut. Thanks

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