Step 3. This is where it starts to get enjoyable. Once your head is completely dry draw a set of basic outlines on your clay so you can see which parts have to be built up. Once you've done this you can start by sticking chunks of clay onto the areas you want pronounced,
You have no need at this stage to be neat, really whack it on and build up the important parts and always make sure its symmetrical. Work the clay smooth with wet fingers until its a rough shape of Ironmans helmet.

Step 1:

Step 4. With war machine there are parts that are a lot more pronounced than others, so, same process as before, wet fingers and whack that clay on and smooth it down so no edges. Feel free before had to draw on the head again the parts you're going to build up i.e the jaw, mohawk. Whilst building them up your going to want to save yourself some work later and smooth it down as much as you can. I used a set of clay modelling tools i brought from amazon for £3 and they were perfect for shaping the edges. 

Once this is done draw on the edges that have to be sharpened up and add more clay to get the right angles your going to need in order to sand them to the right sharp egde shape after. Dont be too fussy as this clay sand really well.

Wait for the clay to dry completely then just go over the whole lot adding little bits of clay to fill in those little holes you think wont sand out and he should look something like the pictures below.

I thought about casting them but its heartbreaking after spending hours making a perfect mould isnt it. Im going to mould my first attempt i think, not as attached to him lol. Thanks chirow.
you should now make a RTV silicone mould of it ( http://www.tomps.com ) with a fiber glass jacket. <br> <br>then you can cast it using fiber glass, and more importantly you can make as many copys as you want, can you say ebay? ;-)
This is awsome !!
Just wanted to say a massive thank you to all who have viewed and passed on feedback, I've entered this competition so if you've made use of or just enjoyed this instructable please vote, i could really do with a laser cutter for the stands im making for the helmets i make. Thank you
Just deepen the first layer of clay because if its your little boys he's probably going to be rough with it. Sorted . . . . . Have fun
Cool thx I got some das clay today just got get a poly head now didn't no if was wearable as seen others use light weight clay but that stuff isn't cheap for the amount needed looking forward to giving this a go
Yes, this one will be wearable, unlike my first instructable. Obviously if u wanted to make it fit perfectly you would need to take a cast of your/your sons head first. The bonus with this clay is the interior, once removed from the poly head, can be trimmed to suit the head its sitting on. Its a really easy n cheap way to make an expensive looking item.
Are u able to where this helmet once finished I desperately wanting to have a go at making 1 for/with my son
Have a go yourself, it really isn't difficult and as i say it shouldn't cost you no more the £30 all in.
How much would u charge to make an iron man head? U can email me waspsoton@icloud.com

About This Instructable


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Bio: Im chris, im a gas fitter and white goods engineer for a large electrical retailer. I enjoy anything that includes me using my hands and ... More »
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