Captain America AoU Project - Going 100% Accurate

Hey guys, these here are some of the pictures of my project for a super accurate AoU Cap suit.

This was my start for the helmet.



Used our tfa cast, but since it was not accurate enough shape ways I went on to modify it with some filler.



I then thought about doing an accurate pattern/texture that I have seen in any helmet on the internet.
That's the first test:



i then did my templates on the computer and proceeded to laser etch the texture on the petg to get this result:



This took many hours and a lot of material wasting.
I had to redo the side panels at least 8 times for many reasons. One being that petg gets very fragile when laser etched:

Anyway, after wasting a lot of time trying to get everything has simmetric as possilble i got to a a point where I was pretty happy with the outcome:



I had to use filler to fill the gaps I would leave between parts of petg:



This was to make sure the petg wouldn't inflate and create annoying bubbles.

 

The final result is shown here:

 

The suit was quite a challenge too, but there's not much to say about. Pictures will actually tell more than words:
Feel free to ask questions if you want

 

Nice job! This is my favourite variant of the Captain America suit by far, and you've certainly managed to do it justice up to now.

 

Looks fantastic!

 

Thanks fellows!

 

You're welcome. The attention to detail here is fantastic, especially the textured detail on the sides of the helmet.

 

this looks soooo great!

 

Excellent Work!

 

Thank you guys!

 

The best Cap's helmet I've ever seen! Did you make it flexible?

 

Awesome!

 

Very nice.
Question: What type of fabric are you using for the costume? I am looking at making a similar styled costume.

 

Yep, I also have a flexible / rubber helmet that fits around 23.5'' heads

Thanks man!

Here it's called panama. That's all I know about it man

 

No worries. I appreciate your help. I recently heard of someone who was using curtains to make their costume. I might go that direction.

 

This is the best looking Cap Helmet I've ever seen. Thanks for the pics.

 

@Pannaus Props your work is really excellent man..i just have one question on what material you made those texture pattern.. i mean did you put that petg on putty or some other material??

 

Amazing job!! Love the progress pics!