How to Build an Iron Man Helmet ! (With Movable Face Plate ! )

People all over the world know about Ironman and he is all of our 's favorite superhero. Along with his trusty ' intelligent ' assistant and his iron (titanium-gold alloy) suit ! Also it has been a long time dream of mine to dive into the world of costumes. So here I have build the famed Ironman helmet. Even though many have recreated the Ironman suits, I loved the opportunity to build the helmet with a movable face plate.

Supplies

Cardboard (of course !)
Superglue/Glue Gun (You can use either of it or use them both synchronisingly.)
Red Spray Paint
Gold Spray Paint
Coat Hanger
Masking Tape
Glue Stick
Paper

Step 1: Template

You can download the template from here.

Step 2: Downloading and Printing the Template

So after downloading the template from above, you should open it with Adobe Acrobat Reader DC.

(If you don't have Adobe Acrobat Reader DC you can download it from here for free.)

Then, click on the printer icon and choose poster and set the tile scale to 100%.

Then you should select which type of paper you are using ( in my case I used a4 sized paper.)

Then hit print.

Step 3: Assembling the Pieces

Trim the edges of the sheets and lay the sheets in order and tape them together.

Then cut out those pieces on cardboard.

Step 4: Building the Helmet

Now lets make the side pieces. Lines colored in yellow are the lines you should cut halfway and those in red are those to be cut fully.

Then push the flaps inwards and glue them.

Step 5: Making the Chin Piece

Stick a piece of paper board (cereal box cardboard) and then flip it over and inserting the inner hexagonal piece will give it a nice sleek detail.

Then cut halfway the lines colored in yellow as we did in the before step.

Step 6: Attach the Pieces

Then stick these pieces together.

Then get these pieces and join them with the helmet.

Step 7: Making the Face Plate

Follow the instructions and glue the lines in green.

Bend the lines in blue forward.

And as followed before, cut the lines in red and cut halfway in yellow.

(Note: Make the mask lightly bendy.)

Step 8: Creating the Back

Glue the lines in green together.

And stick them in the following order.

Then add the earpieces on the sides.

Step 9: Adding the Widow's Peak

Add the widow's peak piece on the top like in the image above.

Step 10: Optional : Tinkercad Modeling

Tinkercad is a very powerful tool used for 3d modeling. It can be used at entry level for basic introduction or even used for complex circuits and models. It can be used by anyone. Also you can make a model in a few minutes. And best of all, its free. So its the most easiest , 10 - minutes, free 3d modeling software available.

Now here I made a Tinkercad model of the ironman helmet which we are building here to check if it would all fit in and also to know how it would all look after the helmet is made. It was also useful in determining the color scheme of the ironman helmet.

(Note : This is optional. You can skip it if you want.)

Step 11: Looping the Face Plate

Now add a loop like this using the coat hanger.

Make the bigger tube using paper movable.

Also add two small tubes on both sides.

Then glue it on.

Step 12: Finished Model

Now the model is ready for painting.

Step 13: (Spray) Painting Time !

Now mask the face plate with tape and its time to give the helmet a metal red spray paint. I needed to give it a 3 - 4 coating to get the metallic finish.

Wait for sometime. Now remove the tape from the face plate and spray paint it golden.