Captain America AoU Project - Going 100% Accurate

Pannaus Props

Sr Member
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.

11011283_914946905205884_2016439464909923923_n.jpg 10989118_914946928539215_6490985986858024486_n.jpg 1510941_914946955205879_2932980597815690143_n.jpg 11002512_914946991872542_546185479095399429_n.jpg

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

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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:

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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.


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Pannaus Props

Sr Member
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 ;)

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Sr Member
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.
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Pannaus Props

Sr Member


New Member
@Pannaus Props your work is really excellent man..i just have one question :p on what material you made those texture pattern.. i mean did you put that petg on putty or some other material?? 11133832_939408209426420_6717031691683887402_n.jpg 11126736_939408496093058_7494092039735238588_n.jpg 10628567_939408559426385_6423749456974413411_n.jpg



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