EvoLutionX`s Iron Man Mark XLII helmet

E

EvoLutionX

New Member
Hey guys,


It was in January when I first found out about this amazing forum and Pepakura and all the things...I was amazed about the things that can be achieved just with paper and foam. And because the German carnival was only two months away I decided to give it a shot with a Mark 3 helmet.
But because I`ve been under time pressure and also did a few greenhorn mistakes, the quality of the helmet wasn't satisfying to me.
You just could see that it was made by hands.

So I`m currently working on my second Iron Man helmet and want to share my progress with you.

I used the Pepakura file from gimpee, thanks for that m8 :thumbsup

But to cut a long story short, I'll just begin with showing you some pictures :)

Here`s the finished Pepakura model next to my first helmet:
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After the first layer of resin:
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What`s my biggest fear every time? Will the helmet be to small?
So right after it was dried I cutted away the back piece and did a fitting test: :thumbsup
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Then I started the filling process. At this point, my intension was to get one area ready before I start the next one:
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Also cutted away the ears:
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filling and sanding:
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more filling and sanding:
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Then I decided to prime the helmet to see where it`s going and to see all the bumps:
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Aaand that`s where I am at the moment :)
Still a long way to go but I'll keep you guys up to date.

Cheers!
 
Hey guys,

I`ve got a little update for you.

I separated the face plate from the main helmet:


Used some bondo to reduce the gaps between the two parts:


Also worked on the jar to prepare it for adding the cheeks:


For that, I quickly designed a template that I will use to rebuild the cheeks:


And last but not least I worked out some details at the faceplate that were missing in the pepakura model:


Furthermore I printed out the backpiece of the helmet again altough I`ve already put in a lot of work. But the symmetry was so bad that I thought it would go faster this way than spending ours of filling and sanding.

Aaand still a lot of work to do..
 
Hey guys,

Right now I'm working on creating new cheeks and could use some help please. I'm a little confused how I can get it really accurate.

So I built a prototype of the cheek how i thought it would look like:


What confuses me is the pictue of RDJ with opened helmet. When the helmet is closed, you can see that the metal looking part which belongs to the faceplate builds one plain with the cheek detail (see the white arrow).
Now how is it possible, looking at the opend helmet, that the two parts are on one plain because there is another detail that gos in the direction where the metal thing of the faceplate should be?
 
Hey guys,

After two months I finally can show you some progress on my helmet.
I created new cheek-parts and made that gap at the chin.
The front part of the helmet is almost done :)
Needs only a few more corrections. Now I`m working on the gap between the faceplate and the helmet.

Long story short, pictures say more than words: ;)




 
Hey,

i haven`t made updates here in quite a while but this doesn`t mean that I didn`t work on my helmet. And finally, the finish line is in sight :)

I got 3D printed ears from a friend of mine


Because the ears are perfectly plane I had to adjust the helmet shape a little bit.


I often had to go two steps back to get one step further. For example I had to remove the cheeks.


But now I can present the almost finished helmet. There is just some detail-sanding left to do before I can start with the molding process.

So here are some pictures:









No I have to make some thoughts about how i make a mold out of the whole thing. Does anyone have any tips for that?
I thought I would make five molds out of it? One mold for each part?

Thanks guys :thumbsup
 
That is an incredible transformation from Pep to almost finished!! I do have a question. For the straight lines on the face plate, did you use something like a file? I was curious because I'm also working on a Mark 42 myself and not quite at that stage.
 
Damnit! It`s almost been a year since my last post and two years since I`ve started with my helmet :facepalm.
At least I can make a Mark 43 helmet out of it now :D.
I`ve tried to make a three-piece mold out of my helmet parts but unfortunately the pieces didn`t fit together after casting.
So I made a one-piece helmet now.
And here are the pictures:

First I prepaired the helmet for the molding process:



Finished mold:


And thats how my first cast came out of the mold



I`m finally satisfied with the result. There are almost no bumps and no air bubbles :)
Only have to cast the ears and look for a good color now.
But it's just a question of a few more months now :D.
Any suggestions which color I should use?
 
Just got to ask. Is this how it's usually done. Casting the entire helmet as one piece. I would have thought that it was done in sections. I ask because i will be trying the same thing soon...GM
 
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