Instructables

How to make a lifesize, wearable Iron Man helmet

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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 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
-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

Picture of Printing and cutting the parts
IMG_20130317_095008.jpg
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: http://www.4shared.com/file/Kd2YFv88/IronmanA4.htm
fcolon212 days 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

Do you cut where the dotted line is?

karora41 month ago
can u plz send d link of pdf for paper markings and cutting
rmiersch jr2 months ago
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?
pheenix422 months ago

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

JK Subhash4 months ago
hey...i'am new at this.so 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 Subhash4 months ago
I haven't got any experience with POP. You can try it, but most people use resin to make the paper model hard.
EKreed20002 months 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.

asianoob3 months ago
hey, how much resin do you need for the whole helmet?

thanks
imaloney4 months 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)  imaloney4 months 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_papabol4 months ago
im new to pepakura.how 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.
spystealth14 months ago
If you can't upload it to the instructable, try emailing it to this email: R2RQ5x9iHFP3@meltmail.com . Great job by the way!
geq1 (author)  spystealth14 months ago
Thanks for the idea! You can download it from here: http://www.4shared.com/file/Kd2YFv88/IronmanA4.htm
spystealth14 months ago
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.
PixelKakashi7 months ago
I see you are pretty good at papercraft, could you please share the .PDO file of the helmet?

Thanks, and good job! :)
geq1 (author)  PixelKakashi7 months ago
Of course! Have you got an e-mail address?
lvathanak geq15 months ago
Hello.. Can you send me the Pepakura file of this helmet?? Thanks you "lyvathanak00179@gmail.com"
DId you design this yourself? I'm trying to make a real life Megaman blaster, and getting the looking right is difficult.
geq1 (author)  forsaknazrael7 months 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.
PixelKakashi geq17 months ago
Sure, it's: pixel_kakashi@yahoo.com

Thanks a lot =D
hardy18125 months ago
cheers matey,,, file received :-)
hardy18125 months ago
could u send them to my e-mail plz matey it's hardy4245@hardy4245.karoo.co.uk 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,,,,
geq1 (author)  hardy18125 months ago
I sent it.
hardy18125 months ago
this is awesome, matey,,, could I ask were u got the 3D image from as I'm thinking ov makin a smaller version for my lad,,have downloaded the pepakura program a would love to know were I could get more of the 3D images from,,,cheers matey,,,unbelievably great post,,,still gunna make this have started lol but keep gluing me fingers together lol,
geq1 (author)  hardy18125 months ago
I made these images with the printscreen button, using pepakura. If you want I can send you the pepakura file or write me which positions you want the images and i make you. :)
Hey so the scale on the PDF is for A4 printing... How accurate is that because I feel its gunna be too small but I think thats just because its on paper not put together. A4 works alright then??
geq1 (author)  meldridge-tull5 months ago
Yes, A4 work alright. If you haven't got much bigger head, then average it must be good for you.
berlintintin5 months ago
Hi! Fantastic work, and thanks so much for putting so much detail online for everyone to share. One question, in step 5, you said:

"The first layer should be only resin on the 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."

Did you mean for one of those to be on the OUTSIDE? Or is there only fiberglass on the inside of the helmet?

Thanks again!
geq1 (author)  berlintintin5 months ago
Hi! I'm glad you liked it! Sorry, I'm not fluent in english. :D There isn't fiberglass on the outside. All of the layers are inside.
vverma86 months ago
hey i am using cardboard to make the helmet . Can i skip the fiberglassing part ??
geq1 (author)  vverma86 months ago
i haven't tried it, but I think you should put at least resin on it.
Tgizzo6 months ago
Thanks! I just taped it up a little because of the superglue shortage :), and it looks great! Thanks so much for all of your help! I really appreciate it :)
geq1 (author)  Tgizzo6 months ago
Your welcome! :) You can order resin from ebay.
I voted for this good ironman helmet
geq1 (author)  Andrew Garfield6 months ago
Thanks a lot! :)
Tgizzo6 months ago
Here is the product :P and where can I find resin? It wasn't at my local hardware store....
13, 1:18 PM.jpg
thanks for reply
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