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    Aug 13, 2012 - Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #1

    Hello friends, i already introduced myself in the sticked thread but i will do it again!

    My name is Mαrio, 26, I'm from Brazil, and recently i started to building an Iron man Helmet to test my abilities and to acquire some practice with pepakura, resining, fiberglassing, bondoing and sanding to build Star Wars helmets and other stuff to have as decoration at my place.

    during the thread i will tell you guys about all the things i'm using to make it, since I'm on a different country i don't have the same stuff you guys have there, and things here are alot more expensive.

    All the credits to the Pepakura file creator (Samuray).
    Here is the assembly of the printed pepakura file:

    Materials used:

    -300g/m² A4 paper (can be compared to 120LB Cardstock)
    -X-acto Knife with several different blades and a sharpening stone to re-sharp the used blades (trust me, this works flawlessly)
    -Super glue and high heat hot glue sticks













    Resining the helmet:

    Materials used:

    -27fl Oz of Ambar Polyester Resin (the strongest one)
    -Universal Resin Catalyst
    -40"X60" Fiber glass cloth (this was too thick so, next time i have to use a thiner one)
    -A lot of 2" and 1.5" wide brushes ( 12 total )
    -Disposable Latex procedure gloves
    -3M 8013 Respirators (6 total, every one gives you 2h to work safe with resin)
    -Sealed Protection goggles ( very important too while working with Resin too)


    1st Coat:









    2nd Coat:






















    well, here its a video of me fiberglassing the helmet, i'm speaking on my native language but I subtitled it for you guys so just click on the CC button to load the subs and enjoy!



    https://www.youtube.com/watch?v=Z1MgoZ7IMF0



    Materials used:
    -Rotary Tool (dremel look a like)
    -Rotary tool Carving & Engraving and Grinding accessories
    -Fiberglass cloth
    -Polyester resin
    -Resin catalyst
    -3M 8013 Respirators
    -Sealed Protection goggles


    I'm going to post the rest of the pictures and other stuff later, i hope you guys enjoy!
    Last edited by memebr; Aug 13, 2012 at 4:45 AM.
  2. NotThePerfume's Avatar
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    Aug 13, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #2

    You're off to a really good start dude!
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    Aug 13, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #3

    It looks awesome!!! better than the one I built. Can you share the pep file you used? I like how it was put together versus the one I used.

    Thanks
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    Aug 13, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #4

    thank you guys!

    The file i used to pep the helmet was the "Samuray Small chin"

    later i'm going to post the rest of the pictures
  5. chinandler's Avatar
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    Aug 13, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #5

    Off to a good start! Very Clean pepping might i add
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    Aug 13, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #6


    Materials used:

    -Polyester based paste (similar to bondo)
    -Plastic based paste (similar to bondo scrtach filler)
    -Small repairs putty
    -Dry Sandpaper of various grids 80, 150, 180, 220, 320, 450, 600
    -Orbital Palm Sander
    -Sander block
    -Rotary Tool
    -small hand saw

    safety:
    -3M 8013 used Respirators (you can still use those for the dust when they are old for organic vapors)
    -Sealed Protection goggles
    -PATIENCE... alot of it!








    Those Lil X's are marking the place that i have to put more "Bondo" to fill it up







    Almoust there:













    faceplate cutted:





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    Aug 13, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #7

    Looks great! Cant wait for the final outcome!
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    Aug 14, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #8

    i was working on the helmet to smooth the faceplate edges, annoying job, but worth it! now the edges are all smooth and tight








    and here is the faceplate, i need to fill some micro holes with detailing polyester paste yet



    Materials used:

    -Polyester based paste (similar to bondo)
    -Dry Sandpaper of various grids 80, 150, 180, 220, 320, 450, 600
    -Sander block
    -Painting mask cover tape (Bondo don't stick to this!)

    safety:
    -3M 8013
    -Sealed Protection goggles
    -Latex Gloves
  9. Shakeitdavey's Avatar
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    Aug 14, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #9

    Brilliant work mate, i'll be getting to that stage soon with my helmet! Great work
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    Aug 15, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #10

    another small update, just showing the 1st PU primer coat

    i hope you guys enjoy!

    Materials used:

    -PU Primer
    -PU primer catalyst
    -Painting Solvents
    -Compressor with attachments for paint job

    safety:
    -3M 8013
    -Sealed Protection goggles
    -Latex Gloves




















    For now on things are going to be a lil slower!

    hope you guys enjoy!
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    Aug 15, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #11

    looking really nice dude! i wish i had the time/patience to make a cardstock pep helmet, i have tried before but took me sooo long to get to where your are right now! so props to you
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    Aug 18, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #12

    Again awesome work. I just recently tried to bondo another helmet for practice and it was really difficult. The bond mix hardens up way to quickly and i really want to do this step for my iron helmet. How is working with polyester based paste versus bondo? I was also thinking about using plaster but not sure if it sill give me a nice smooth texture like bondo.The iron man helmet I'm making is for display.
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    Aug 19, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #13

    very nice
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    Aug 21, 2012 - Re: Iron Man MKII Helmet, my 1st BUILD + video! (Pics Heavy) #14

    CensoredAwe said: View Post
    Again awesome work. I just recently tried to bondo another helmet for practice and it was really difficult. The bond mix hardens up way to quickly and i really want to do this step for my iron helmet. How is working with polyester based paste versus bondo? I was also thinking about using plaster but not sure if it sill give me a nice smooth texture like bondo.The iron man helmet I'm making is for display.

    Polyester based paste is a product like bondo, have the same features as bondo has

    try to work with a "colder" mixture (when you use a lil less hardener catalyst), i like to work with cold mixtures, cause it gives me more time to apply and play with the bondo around the helmet.

    i just use hot mixtures when i need a certain area to be hardened really quick (when i pass trough the resin and i need to fill the hole, for exemple).

    try this: for a golf ball size amount of bondo use half a pea size amount of hardener, this would give you an nice cold mixture and plenty of time to work with it.

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