MK50 IRON MAN BATTLE DAMAGED ENDGAME TRAILER HELMET

Discussion in 'Marvel Costumes and Props' started by iamshazam, Jan 28, 2019.

  1. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    I figured it was about time I post a build after being a long time member and silent builder...I am currently working on a 3D print / build of the MK50 battle damaged helmet from the Avengers Endgame trailer. I'll be posting update pics and such here as I go and will provide the build video links once they are ready.

    The plan is to complete the build in time for the movie release. I'm aiming to build the helmet as accurately I am able to. I'll be learning to work with my new airbrush set along the way (had always used rattle cans and brushes in the past - and I will probably SCREAM out pleading for some guidance once I get there) and finish the piece with lights and sound (I've mapped out the LED sequence and will include more info about that later on).

    I looked at the models on Thingiverse by DamaskProps and MyMiniFactory by T-E-C, but neither really worked for me (I mean no disrespect, they are great models and show great work and talent). I wanted to be able to separate the parts differently and it would've been too difficult to separate the parts in those models. I decided to go with Do3D's model (model link), but made some alterations to make it a little more screen accurate - don't get me wrong, the model is great as is!!

    I'm including a few model comparison shots for anyone that has been considering this build and these models along with the final adjusted model that I am working from...

    MK50 Model Comps Front View.png MK50 Model Comps Back View.png MK50 Model Comps 3.png CHWcosplay:Do3D MK50 Battle Damaged Endgame Helmet Adjusted Model.png
     
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  2. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    I forgot to mention that I will be primarily printing this on the Prusa MK3 and using Slic3r (recently switched from Simply3D)...

    Here is the slice of the main helmet, I originally had it sliced into 3 parts which had a relatively decent print time and had started printing the parts (before making the adjustments to the model - I was too excited to start!), but then changed my mind and re-sliced it after making the adjustments to reduce the final amount of parts needing to be assembled.

    Sliced this way, at 0.1mm layer height with a 0.4mm nozzle, the total print time for just this part is 60 hours. This is my longest single run printed part!! In the past I would have sliced the model based on details and for and printed the parts with less on my Prusa MK2 which has a 0.6mm nozzle on it currently and set the layer height to around 0.3mm or 0.25mm, but I am trying to move away from that process for smaller builds like this.

    Would have been great if the print didn't fail 30 hours in!!! There was a single support post in the back right that I had a feeling might fail, but rolled the dice thinking if it did it wouldn't jeopardize the entire print...but I was wrong. The air-printed material after it failed started to catch the support structure near it and began lifting the entire section off the bed when it caught the extruder.

    MK50 HELMET MAIN FRONT SLICE.png

    MK50 FRONT MAIN PRINT FAIL.png

    MK50 FRONT MAIN PRINT FAIL CANCEL.png
     
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  3. GEEK1138

    GEEK1138 Sr Member

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    Nice work...I will watch with interest
     
  4. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Thanks GEEK1138

    I sliced the inner parts of the faceplate in half to print on each side, it was a bad idea - the supports are way too much of a nightmare to deal with in some areas due to the orientation. I made a new gcode file with it laying flat and I've dropped the layer height to 0.05mm. This will be the first time that I am printing at that level, but the details of the part are worth a second 60hr print!!

    I am also printing on all of the remaining parts strictly from the SD card and not taking another chance with Octoprint, not until I can correct whatever the issue is that caused it to crash before.

    inner Parts on Side Printing.jpg Half of Inner Part Printed.jpg
     
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  5. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    The Octoprint issue...50 hours in to the 53 hour print of the front sliced part of the helmet the server crashed and froze!! I printed the remaining chin part, glued it on and will only print from the SD card moving forward with this print.

    Octo crash during front helmet print.jpg Repaired Front Helmet Chin.jpg Repaired Front Helmet Chin 2.jpg
     
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  6. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Evidently I didn't learn my lesson, but in all fairness I thought that the supports were low enough to be able to get away with a single support beam without it failing...wrong!! And there was no sign of a problem just a few hours prior.

    27hrs in to a 65hr print -- FAILED SUPPORT

    INNER PART 41HRS LEFT.jpg INNER PART 38HRS LEFT.jpg INNER PART FAIL.jpg
     
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  7. StolenBlackMesa

    StolenBlackMesa Jr Member

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    I’m glad you’re still pushing through this project even after all your troubles! Dit give up! This build is looking very very promising
     
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  8. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Thanks! This is nothing! I had a printer fail so bad that it wrecked the extruder carriage 1 week before Comic Con and almost derailed my build...I was finishing the paint work less than 24hrs out - I was really scared/* that I could be the guy that smells like fresh paint (I didn't, cause it was acrylic airbrush mostly and dried fast). I was Star Lord / Deadpool (cheesy mask) mashup.
     

    Attached Files:

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  9. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    After 75 hours and 55 minutes the inner part is DONE!! There was one slight failure, but it's on the side under the faceplate so it won't be very noticeable, but I will still probably fix it regardless. Let the sanding, filling, sanding, filling, sanding, drinking, sanding, drinking, filling, drinking, drinking, sanding, drinking, remembering what I was working on...commence!!
     

    Attached Files:

  10. The14thDr

    The14thDr Sr Member

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    This is looking GREAT!! The level of detail in this is mind-blowing. I'm insanely jealous of members who have access to a 3D printer and I can't wait to see how the rest turns out! :)
     
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  11. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Not only did my whole way of building and creating change after I got my first 3D printer, my entire workshop has been elevated to a whole new level and I know I am no where near done working on the room - it really pushed me to step up my game (well gave me more of a reason to create a better functioning work/man cave - my girlfriend calls my printers my "other girls").
     
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  12. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Printing test lens settings while procrastinating sanding...and doing paint color research...


    IMG_1262.jpg IMG_0938.jpg
     

    Attached Files:

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  13. mikid

    mikid Sr Member RPF PREMIUM MEMBER

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    Cant wait to see the final product...looks pretty cool!
     
  14. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Finally was able to get a little work done on the build and about to get back into some more sanding and post work now...

    IMG_1331.jpg IMG_1332.jpg IMG_1333.jpg
     
  15. StormyStorm

    StormyStorm New Member

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    Looking great! Good work so far, I can't wait to see the progress.
     
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  16. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    I've been researching paint colors and processes (and techniques as airbrushing is still new to me), the suit definitely has a unique color to it compared to previous ones. I even spoke with the original artistic designer about the color scheme for the suit. I've narrowed the options down to 2 possible colors and I think I will test several application methods.

    Paint Option 1: Alclad II ruby red - I am going to test several base coat options other than their bright candy base. I don't think that their candy red is the right tone of red, but I may test it as well with different base coats under it to see how it comes out.

    Paint Option 2: Firemist - a automotive paint that I will decant and airbrush over a few different base coats as well

    Any thoughts, tips or suggestions?


    IMG_1340.jpg 1RUBY-RED.jpg 118019d1194915683-thulite-red-storm-red-firemist-red-amber-red-mb-203.jpg

    1RED-A.jpg
     
  17. Jediguy

    Jediguy Well-Known Member

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    I just ordered a 3d printed kit and am following your thread. I was also wondering about the paint colours
     
  18. Shakeitdavey

    Shakeitdavey Well-Known Member

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    This is going to look sweet!! Keep the pics coming.
     
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  19. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Decided to see what I could do with what I already had in the workshop before ordering new colors. All WIP still and I have a few more to go that the primer is still curing on. C87923D7-F3D7-499F-B387-70CC18146FBF.jpeg
     
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  20. xl97

    xl97 Sr Member

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    top right pic looks great IMHO..
     
  21. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Thanks, I like that one too, it’s a little too deep when not in a lot of light though, which is probably the byproduct of the matte black primer base coat and the shade of metallic “chrome” I used (I was out of gloss black and white and had the painting itch). I’m happy to know what can still be achieved with a matte base coat. I’m also going to test some satin clear coats as the suit has a more satin sheen to it than a real high-gloss. And I’m going to get the right color red to mess with!
     
  22. Manchester07

    Manchester07 Jr Member

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    I would love to buy one of these from you once you are finished i loved the look of Tony's battle damaged mk50 helmet from the first time i saw infinity war. Please dm me if you would consider making one for sale
     
  23. Abb eliten

    Abb eliten Active Member

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    This look really good!
    The paint is a real pain to decide
    As you said, a satin finish wouldn't be bad at all, the latest pieces I painted, I skipped the clear all together and I'm really happy with it
     

    Attached Files:

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  24. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    That paint job looks great!...what is it? Almost looks like the Toyota or Colonial red with a satin sheen to it, but I don't think it is...

    I was watching the movie on 2 different tvs in the house (seeing if there were color differences) and there was a little more gloss (or depth) than in some of the pics I've been staring at, but not much. I continued my crazed tests with whatever paints I had in the house, until I purchase more - and I focused on the first and second layers, still need to add the top clear red with a satin finish. I'm really just procrastinating because it's been way too cold to hit the primer on the parts outside (I hate spraying the primer in the airbrush station, it stinks for DAYS no matter what). Everything I tried to paint outside over the weekend took so long to cure that it started either to freeze & crack and/or got extra dirty from the air since it wasn't drying fast enough. And I'm having fun with my new airbrush and have been making mini pegboard systems for the workshop.



    IMG_1435.JPG IMG_1427.JPG
     
  25. Mikesnead

    Mikesnead New Member

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    Love your work soo far man! I recently purchased the Do3D files as well for the damaged MK50 helmet and was wondering if your edited/modified files were for sale? I love the added detail that you incorporated into the helmet, I attempted to do the same but I'm not getting the best results.
     
  26. viva0101

    viva0101 New Member

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    Hello everyone! These are the Iron Man Helmets I made in the past two years.
     

    Attached Files:

  27. Abb eliten

    Abb eliten Active Member

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    Thanks!

    I only have the number of the paint from a local store
    I've tried to find a color code name for that red in their car paint guide, and the only one I could find was Toyota Ginger Red
    Now I'm not sure that's a 100% match. These colors are a bit universal for a lot of different paint jobs.
    When I picked the color I browsed all their red metallics and picked the one i liked the most.
     
  28. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Thanks!
    I'm pretty sure it's in my saved list on Amazon, hoping I can make some time to play with the Tamiya paints that arrived.
     
  29. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Did a little LED test on some spare parts

     
  30. iamshazam

    iamshazam Member RPF PREMIUM MEMBER

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    Been slow on the work since it's been way too windy to hit the parts with more primer and regular life and work (boring!! haha), but got a little more sanding done and made a little portable dev board for the faceplate (that's an early test print on the dev board). Hit a different red with some Satin finish, think I'll add a few more coats today while the wind is calm - it's really hard to get a good pic of it as it comes off looking more metal flake than it actually is.

    IMG_1480.jpg IMG_1492.jpg IMG_1493.jpg IMG_1506.jpg IMG_1508.jpg
     
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  31. xl97

    xl97 Sr Member

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    +1 for Arduino!
     
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