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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simong1133 made it!23 days 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.


Cool Version of the helmet

Cool Version of the helmet

hshahzad12 months ago
can you give the video please
timojloo3 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 :)

afriyann3 months ago

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

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

nikola.kucar7 months ago

Do you have pep file?

BartłomiejH8 months ago

A good job, I'm impressed 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

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.

yodi.shadow9 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-vega11 months 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......

yes you could. you can use the bandages that come ready, as for casting a broken arm, or the powder to mix with water.

geq1 (author)  JK Subhash1 year ago
I haven't got any experience with POP. You can try it, but most people use resin to make the paper model hard.
EKreed20001 year ago

Love the instructable geq1! Just have a question. Do you know what sections form up the back section of the helmet that way I can set those aside for a later section of the project. Im making a customized version of this helmet for a custom character for a convention Im going to and not 100% sure i want the lower section of the back. Any information would be helpful! Thanks.

asianoob1 year ago
hey, how much resin do you need for the whole helmet?

imaloney1 year ago
Hi so I'm making a similar mask and really like the backlight LED eyes but its really important for me to be able to see out. How well can you see out with the tiny slits in the eyes or have you come up with a better design to improve vision?
geq1 (author)  imaloney1 year ago
Hi, I'm going to improve the helmet with a motorized faceplate, so I don't always have to see out with the slits, but I think those are big enough to see people's faces and don't fall over. :D
mr_papabol1 year ago
im new to did you add the corresponding numbers to the flaps? i have downloaded another pdo file to make another 3d project but when i change it to pdf, it doesn't have any corresponding number to it, so im having a hard time to match up the parts.
If you can't upload it to the instructable, try emailing it to this email: . Great job by the way!
geq1 (author)  spystealth11 year ago
Thanks for the idea! You can download it from here:
I think it would be best if you uploaded the pdo file too so people could use pepakura viewer to guide them along. I don't want to have to give my email, I just want to download it like I did the pdf file.
I see you are pretty good at papercraft, could you please share the .PDO file of the helmet?

Thanks, and good job! :)
geq1 (author)  PixelKakashi1 year ago
Of course! Have you got an e-mail address?
lvathanak geq11 year ago
Hello.. Can you send me the Pepakura file of this helmet?? Thanks you ""
DId you design this yourself? I'm trying to make a real life Megaman blaster, and getting the looking right is difficult.
geq1 (author)  forsaknazrael1 year ago
No, I found the pdo file on the internet and I made the pdf version of it. Unfortunately I can't help you, but I recommend you to google: megaman blaster pdo.
Sure, it's:

Thanks a lot =D
hardy18121 year ago
cheers matey,,, file received :-)
hardy18121 year ago
could u send them to my e-mail plz matey it's still trying to use the program so if u could send the file I can have a mess about with it,,,cheers matey,,,, started makin it tonite it takes a while hahaha but I'm getting there,,,,
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