I've been wanting to build my own Mark I helmet for a few years now...the shapes and details of the helmet seem basic enough that I think I can whip something up pretty quick.
The goal is make the helmet all metal, yet light enough to wear comfortably. The thickness of the metal will have to...
I put together this Iron Man Mark 85 Cosplay Foam Helmet Tutorial using Pepakura file templates and EVA Foam.
I'm looking to built the entire suit. I'll decide in a week or so.
I'll post that project vlog here when the time comes.
Check out the video if you'd like to make your own Iron Man helmet: