IM Helmet advice needed

[chainmailchan]

Hello guys, my first thread here. I've been fascinated with the work of everyone here for months and ive been working on my first pep helmet. Ive been having trouble with the process though..

Oh just to explain a little of my initial troubles.. I'm from Singapore (SouthEast Asia) and automotive DIY isnt big AT ALL here so ive had to source epoxy resin/fiberglass cloth direct from factories and ive to buy bondo (am using U-Pol Fly Weight) from an obscure paint shop.. If anyone else is from around here and know where to get better/cheaper materials I'd very very much appreciate it!

Back to the point, I started this thread because I need advice on how best to cut the grooves into the iron man helmet after ive bondo-ed it..


this is the helmet at the moment.. did a light coat on the faceplate to see its imperfections..

Trying real hard to follow the pep lines and i tape up wherever I'm not adding filler at that pt..

ive also used a dremel cutter to cut out the lines below the mouth area but the circular cutout wheel is limiting..

yesterday I tried using an engraving attachment and it cut out the lines better but I know theres no way I'm going to get the grooves with an even depth this way... help anyone? my only idea atm is to bondo over every damn thing, sand everything out THEN cut the grooves out. yes? no? maybe? I dont know~


also... HOW DO YOU GUYS GET THIS AREA DONE?! ):


Front view.. need to do major reshaping on the cheek area as you can see..

In any case, thank you for reading and I welcome any advice. Love this forum!


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[herotrooper]

Hey,

You are going in the right direction, so don't give up. Most people reinforce the interior of the helmet and then separate it into 3 pieces to smooth out and add details where necessary.

I would really suggest checking out other Ironman projects to see how other people on here...

Here's one : http://www.therpf.com/f78/ironman-mkvi-pep-helm-aiming-99-movie-accuracy-blink-fade-led-eyes-124100/

 

[chainmailchan]

Hey,

You are going in the right direction, so don't give up. Most people reinforce the interior of the helmet and then separate it into 3 pieces to smooth out and add details where necessary.

I would really suggest checking out other Ironman projects to see how other people on here...

Here's one : http://www.therpf.com/f78/ironman-mkvi-pep-helm-aiming-99-movie-accuracy-blink-fade-led-eyes-124100/

oh wow ok he didnt go into detail but I see he did the bondo over then dremel!! I will do the same!! thanks a lot.

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[chainmailchan]

Looks like I'm finally checking this experiment "done"! This marks the end of my very first attempt at...
Pepakura
Epoxy resin
Epoxy with filler
Fibreglass
Body filler
Bondo w/ fibreglass
CA glue and baking soda
Lots of Sandpaper
LEDs
Spray paint

Apologies for my noobness and I look forward to my next project and learning so much more from you guys!!




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