How to make a lifesize, wearable Iron Man helmet

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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.
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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.

Step 2: What will you need

Picture of What will you need
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
-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)

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

Picture of Printing and cutting the parts
The mask has a paper base, which is designed by a program named Pepakura. It makes 2D parts from a 3D model. Fortunately, you don’t have to design the model, here is the .pdf file. You have to print them to hard paper. Normal paper doesn’t work perfectly.
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:
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MridulA123 days 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.
MridulA123 days ago
MattL628 days 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)  MattL628 days ago
The pdf was designed for a4 paper. If you printed it to a4 it should be the right size.
Nice! Do you know how I could get the mask to open up? And how much did this helmet cost overall?

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.564811 month ago

About 25x18x22 in centimeters.

nikola.kucar9 months ago

Do you have pep file?

geq1 (author)  nikola.kucar1 month ago

Yes, the link is in step 3.

BartłomiejH10 months ago

A good job, I'm impressed

geq1 (author)  BartłomiejH1 month ago

Thanks! 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) month 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)  CaptainRex21211 month ago

Yes, every number goes to the same number.

afriyann5 months ago

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

geq1 (author)  afriyann1 month ago

There are tutorials on youtube from other people.

timojloo5 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)  timojloo1 month 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!2 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)  simong11331 month ago

Your welcome. Nice prop.

EricVera5391 month 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)  EricVera5391 month 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 =>

As well this one =>

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

Hope this helped!

teena.tobey1 month ago

Cool Version of the helmet

Cool Version of the helmet

hshahzad14 months ago
can you give the video please
yodi.shadow11 months ago

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?

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

Do you cut where the dotted line is?

karora41 year ago
can u plz send d link of pdf for paper markings and cutting
Love it, I'm trying to make it now for myself, where did you buy the paper at? Or if you made it how much if you were to sell it?
pheenix421 year ago

Too bad I can't make a motorcycle helmet like this!

JK Subhash1 year ago
hey...i'am new at i just wanted to know if i coul use POP[plaster of paris] for hardening.

Great instructable......
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