Sintra Iron Man Helmet Build

[Mogul42]

Hello, I recently posted my Star Wars respirator masks I made out of Sintra. They were a lot of fun to build. I am continuing my work in Sintra. I'm refining my technique and what not. In the age of 3d printers I still have a huge sheet of Sintra and it's an interesting medium.
I'm starting on an Iron Man Mark VII build. I wanted to start sharing my progress. I am using Omarbou's paper craft pattern. I made a card stock version and reinforced it with a little fiberglass to use as a template. Then I'm using their foam pattern for the Sintra. Here's my start.
I shape it with a heat gun, and push it against the paper craft. I'm trying welding the seams with a wood burner soldering iron. I know it creates fumes but I am taking precautions.

 

[Mogul42]

Hello,
I thought I would be moving faster than to have my second post be so long after the first. Now that I have something more I am pretty happy to get the face plate to this stage.
I am pretty happy with how the plastic welding is going. I know about the fumes, but I made a fume extractor for this. The best part of the welding would have to be the spot welding. It makes placing the pieces sturdy, but I'm still able to work with the shaping if I need to. I also don't have to worry about a glue not holding, or waiting to dry.

 

[Cbstudios]

Looking great so far!