Aluminium Iron Man Mark II Replica Prop

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RogueSkynet

Active Member
I have been working on a replica flight test Mark II version Iron Man helmet.
I started with a rough cast that needed some initial clean up with some files and a dremel.
Once the first clean up was done, it was time to sand to get a nice even finish. It took a while but was worth it.
then onto polishing.
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ScoobiJohn

Active Member
would love to see your process in making these - they look fantastic and i'm trying to build some props from real metal and hit some road blocks and looking at thousands to get new/better tools to sort them :)
 

RogueSkynet

Active Member
would love to see your process in making these - they look fantastic and i'm trying to build some props from real metal and hit some road blocks and looking at thousands to get new/better tools to sort them :)
I didn’t cast the helmet, just the bust. The rough casts can be purchased on WISH for the Mark II. I finished the cast with lots of sanding and polishing.
The bench grinder I use for polishing was £80.00
The other tools I use are, files, dremel, drill etc. All basic hand tools apart from polishing. When casting you need a lot more, like when making the T-800 bust. I had to make high heat molds with Mold Max 60. You can pour low met metals into that silicone.
Otherwise it does get expensive with investment casting. Sand casting can be done but not for complex shapes.
 

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