When I started building the Iron Man helmet , I had great difficulty on making the earpiece.After a few mistakes and hours of sanding, I had an idea that works quite ok for me.
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Step 1: The Material Needed:
40ml of polyester resin
01 spray can cap
01 plastic cup
Step 2: Let's Start!
First in a plastic cup we are going to add about 40ml of polyester resin.
Normally I put 10 drops of catalyst to accelerate the hardening process.
Step 3: Pouring the Resin Into the Spray Cap
After mixing the resin, you must pour directly into the spray cap.
It's not necessary to use any mold release!
Step 4: Removing the Resin From the Spray Cap.
wait about 1 hour to remove the resin from the spray cap.
After removing the cured resin from the spray cap, the piece should look like the one from the picture above.
Now with a marker, outline the craft stick and cut along the line drawn..
You can cut along the line drawn with a dremmel or a small cutter.
Remember! If you are underage ,you must ask your parents for permission!
Step 6: Sanding.
After sanding , the earpiece should look something like the pictures from above..
Step 7: Final Step.
You can use a bit of modeling clay to fill the middle part.
I added about 4 mm height of clay and made a mold.
That's all folks!