Any tips making a Foam Iron Man helmet?

[gannikus]

I just have one quick question, this is my first time and I want to try and make a Mark VI helmet. I got most of the equipment to do it except the foam, what size foam should I buy for the helmet? Do you guys know any videos I can watch for a tutorial? I have an idea of how to do it though. xrobot's video is very helpful

 

[msleeper]

Tip #1: Don't start with the helmet.

 

[joker53]

Even if you wanna start with the helmet.. dont use thick foam and don rush your work

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[joker53]

Here's how I do mine

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[gannikus]

Here's how I do mine

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What size foam did you use? I have some 2mm foam lying around my house, is that enough or should I get thicker foam?

And is there a specific piece I shouldn't glue to be able to build the face lift (to open and close it)

 

[Mektar]

Theherotutorials,Xrobots,starkswarehouse and Drack got some very helpful tutorials on foam building. I actually use 10mm foam but you can use whatever you want i guess.

 

[joker53]

2mm should be fine as long its soft and flexible.. Glue the helmet together .. Coat it with sumthing so tat the piece is rigid.. Then cut out the piece... Dun forget.. Dun rush your work I start mine from the chin - face plate then back.. You try which is comfortable to you.

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[IMIM2]

Gannikus

Sorry, IMO 2mm is just too thin. I tried to make 1:2 scale helmet, it still too thin. It'll wobble too much. My first trial is using 3mm, but my preference is 6mm.

If you have 2mm, you can glue it together to make 4mm and start from there. Or, you can use 2mm to build, and then line it up with another 2mm layer.

I made a thread for foam build tips, fell free to read.

@Joker53: I had similar situation and picture for helmet making :lol

 

[joker53]

Gannikus

Sorry, IMO 2mm is just too thin. I tried to make 1:2 scale helmet, it still too thin. It'll wobble too much. My first trial is using 3mm, but my preference is 6mm.

If you have 2mm, you can glue it together to make 4mm and start from there. Or, you can use 2mm to build, and then line it up with another 2mm layer.

I made a thread for foam build tips, fell free to read.

@Joker53: I had similar situation and picture for helmet making :lol

Same as mine??

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[IMIM2]

I started with making helmet too, and this is I ended up with

Two more just died gracefully before I took the pics.
I used this picture as a warning for anybody to not start with the helmet as first project (see my #7 tips)

This is my latest collection:

Some of them are a keeper, some of them are junk. Some already thrown out as trash, some were given to my friends kids

All in the name of learning curve.

 

[joker53]

I started with making helmet too, and this is I ended up with

Two more just died gracefully before I took the pics.
I used this picture as a warning for anybody to not start with the helmet as first project (see my #7 tips)

This is my latest collection:

Some of them are a keeper, some of them are junk. Some already thrown out as trash, some were given to my friends kids

All in the name of learning curve.

Here's anothet tip.. Helmet dont turn out good keep it.. Salvage parts of the helmet to your own custom helmet like im doing pepper pot rescue invincible ironman... You'll be amaze of wat you can do .. Chin from iron patriot.. Face plate iron man extrimis.. Top iron man mk 42

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[EyeofSauron]

Gannikus

Sorry, IMO 2mm is just too thin. I tried to make 1:2 scale helmet, it still too thin. It'll wobble too much. My first trial is using 3mm, but my preference is 6mm.

If you have 2mm, you can glue it together to make 4mm and start from there. Or, you can use 2mm to build, and then line it up with another 2mm layer.

I made a thread for foam build tips, fell free to read.

@Joker53: I had similar situation and picture for helmet making :lol

used 2 mm foam on mine, but doubled it up some places, still, it works well. with coating and padding, its fairly rigid.

 

[IMIM2]

If you have 2mm, you can glue it together to make 4mm and start from there. Or, you can use 2mm to build, and then line it up with another 2mm layer.

That's what I said earlier, use liner (inner layer) to strengthen it.Then we got 4mm.

PS: like your helmet. It has rustic effect. Dare to be different thumbsup

 

[babar]

[ Tip #1: Don't start with the helmet. ][/QUOTE]

any reason why dont start with helmet?

 

[babar]

Tip #1: Don't start with the helmet.

any reason why dont start with helmet?

 

[outlookaj]

any reason why dont start with helmet?

You don't start with the helmet because it is easily the most difficult piece of the suit. I tried starting with the helmet about 3 times and then scrapped them all and moved onto the chest and back. That got me a better understanding of foam building and how to make it easiest on my self. and then went back to the helmet.

Best advice is to go slow, don't rush it. And make sure to coat it with something/ make it rigid before you cut the faceplate off or it won't hold it's shape.

Good Luck!

 

[Drack]

So I guess I should add a little about my experience with making foam helmets. Although its not the easiest part of suit it was the first thing I started with and the first thing I had made from foam. I used 10mm foam although 5-6mm is probably better in my opinion as long as its a nice dense foam. If you heat your foam up well to shape it then you shouldn't really need reinforcement but a bit of wire on the back of the faceplate wouldn't hurt cause over time with use it may try to go back to its original shape a little. I must admit I actually think the helmet is one of the least hardest parts of the suit as there are not many thin or small parts so if you take it slow and think about each piece before cutting it then you should be fine.

Good luck and if you got any questions then hit me up on my thread.
Tom.

 

[nights]

Hey, I just started building my Iron Man Helmet and it turned out pretty well, keep your head up. Its not as hard as it may look.

 

[Mig407]

heres a few random tips:
- learn to use the "check corresponding face" function on the pepakura program.
its an awesome tool. helps you see how parts fit together. (just right click on the parts)l
-practice with cardboard before you try the foam. cardboards cheap and many times free. after about your third one you get pretty good at it. its also a great lo-tech way to determine proper scaling for your head and fine tune your templates. like if a certain scale is ok height wise but you need it a little wider etc...
- make it in sections: i start with the chin then i make the cranium part minus the last lower back level so i can try it on. leave that for last. then i do the faceplate.
-take some time and watch all of stealths tutorial videos. also read up on jfcustoms foam building threads.

great tutorial on general foam building tech
How To Make Halo Spartan Armor

 

[Mig407]

just an example of one of my practice helmets