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

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

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

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:

Step 4: Gluing the Parts Together

You can use almost any kind of glue you want. I tried glues and the Technokol  Rapid universal glue worked the best for me. It dries fast, so you don’t have to wait much.
As you can see there are two of every numbers ont the parts. Every number goes to the same number. It helps you to match the parts together.
The helmet will have a drop down back, so don’t glue it to the front part.
There are two triangular parts. You need those parts until you resin the helmet. They hold the two sides close until the helmet hardens. After that you don't need them. You can see on the pictures where you should put them.

Step 5: Resin and Fiberglass

The polyester resin and the fiberglass makes the helmet strong and durable. The first layer should be only resin ont he 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.

Step 6: Filling and Sanding

I used Trinat filler, which is a one component, resin based filler. I added about 3 layers and sanded after each layer. The numbers of the sandpapers I used were 60,120 and 360. I This step takes longest time, so be patient.

Step 7: Painting

I used masking tape to cover the places I don't want to paint. The paint sprays I used were a metallic gold and a rally red. I painted two layers.
It is highly recommended to paint the inside too, so you don't have to inhale the resin.

Step 8: Making the Back Part

The method is the same: Resin, fiberglass, fill, sand, paint. In the real Iron Man helmet the ears are not just a simple circle, but on the paper base they are. I made the original ears from a 3mm thick wood plate and glued a piece of plastic to the bottom of them. After that I glued the ears in place.
You can't put your head inside until you have removed the back part, so you'd better use magnest to make it removable.

Step 9: Making the Teeth and the Eyes

The teeth are two piece of wood (10cmx2.5cm) with thease engraved lines. I painted them black and glued inside the helmet  using hot glue.
The eyes are LEDs behind scrached transparent plastic (you can get it from for example plastic cups). You can scarth the plastic using sand paper. Then you should glue the LEDs using hot glue. After that, you have to add a piece of aluminium foil or beer can to reflect the lights. Don't forget to leave a few milimeters under the eye lights, so you can see trough.

Step 10: Wearing :)

Congratulation! You have finished your own Iron Man helmet! :)
I hope you enjoyed this tutorial as I did making it.
If you have any questions leave a comment or send me a message.

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199 Discussions


Question 4 weeks ago on Step 3

good morning how are you i want donwload the pdo but 4 shared say The Pdo no available


Question 4 months ago on Step 6

Can I see a picture of the back of the helmet before the part with the ears on it was added


Question 5 months ago on Step 3

Can you please tell me which part of the template is the face plate? Please! I'm stuck on that!


Question 7 months ago

Hey can anyone please explain just how to put this together? A video maybe?


Question 1 year ago

Link of PDO doesn't work, could you reaload it please?


2 years ago

Dude I have to say this is an epic result. Ive made about 5 in total now and they arnt easy. There are various examples out there and triple the amount of files but a real credit to you this is fantastic. Brilliant work from one builder to another


2 years ago

Show me how to cut the template


2 years ago

have u ever considered making moulds of your original helmet?


3 years ago

I'm making the face of the iron man helmet.


3 years ago

can't we wear the whole helmet including back part or we can wear only front part


3 years ago

Hey man i printed the pages from your pdf you provided .. 17 pages... well im wondering how to cut them and then where to fold .. some of straight lines are like so close .. i wonder how to do it.. kindly help


3 years ago

As regards to the dotted fold lines, are they all folded the same way and how do i distinguish between which bits fold which way

1 reply

Reply 3 years ago

Dash dot dash are vallet folds, and dash dash dash are mountain folds


3 years ago

This is amazing. Well beyond my grasp unfortunately, because I definitely do not have the right materials. Well done. I'm seriously blown away by your handy work on this.


3 years ago

can i use construction paper


4 years ago on Introduction

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.

3 replies

Reply 4 years ago on Introduction

Unfortunatelly, no. Maybe with simpler models, but not with this. You can order from ebay too.