MF's Iron Man Helmet Builds - Mark 3 and 3D Printed Mark 42

Re: MF's Iron Man Helmet Builds

Mark 42 Build Starts Here:

Hey guys! A year is a long enough time to go without updating, right?

Essentially, I started this build thread with a friend when I was 16, now 20. The Mark 3 helmet we started with did eventually get finished, but after a failed molding and realizing it wasn't too accurate or well crafted, we more or less lost hope in that build. After a while, we then printed the Mark 45 that I modeled, but nothing really came of that since we were only really building it because it was new at the time, and not because we liked it. My buddy printed Gimpee's helmet (post above) and he finished that and loves it. I always feel a bigger sense of pride doing things myself, so I decided to make the Mark 42 Helmet since that is the one I love the most. I modeled the helmet a while back but just recently started printing it out and finishing it. The two videos below follow my progress of the build. Do note, that the helmet in the first video was actually sold, and I am currently printing/finishing a new one. More updates to come soon!




Some screen grabs from the finishing of the rear part of the helmet:

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Re: MF's Iron Man Helmet Builds

This post looks amazing, I have already made a foam helmet and most of a suit, but looking back on it I see all of the sloppy errors. What materials would you suggest if I was to try to make a helmet with great details like yours? Also, do you suggest making a cast and then re molding that and creating another one, or perfect the first model and make a final cast.
 
Re: MF's Iron Man Helmet Builds

This post looks amazing, I have already made a foam helmet and most of a suit, but looking back on it I see all of the sloppy errors. What materials would you suggest if I was to try to make a helmet with great details like yours? Also, do you suggest making a cast and then re molding that and creating another one, or perfect the first model and make a final cast.


Well thanks! Firstly, the molding, casting, and remolding was only brought on by mistakes and should never have to be done since it is a waste of money, time, and materials. As for building, if you have the means, I suggest 3D printing all the way. It's super clean, little effort, and saves a lot of time in the finishing stage. The only downside to it is it takes a while to actually print the parts. But if you don't have access to it or simply just like doing things yourself, the good ol' fashioned pepakura and fiberglass method (that was the main way of doing things before foam and printing was popularized) is your best bet.

Boochieboy on YouTube has a great tutorial series (<---Link to playlist of the series) that goes over every step of creating a very accurate Iron Man helmet using Pepakura, fiberglass, body filler, and simple home tools. I recommend watching all of the videos in the series first to get an idea of what you're in for, then going back and watching them as you progress through each stage.

Hope this helps! If you have any more questions, feel free to ask
 
Re: MF's Iron Man Helmet Builds

Thanks a ton, I just finished all of the videos. How large should i make the helmet, I'm wondering how large you made yours to advise me how large mine should be. I'm pretty tall so I don't want it to look to small, but also don't want to look like a bobble head.
Thanks again!
 
Re: MF's Iron Man Helmet Builds

Thanks a ton, I just finished all of the videos. How large should i make the helmet, I'm wondering how large you made yours to advise me how large mine should be. I'm pretty tall so I don't want it to look to small, but also don't want to look like a bobble head.
Thanks again!

Ohh man. I never saw this question. Hopefully you got everything scaled properly!

But I do have an update on the Mark 42 Build! I'm still slowly making progress on the thing (and hope to actually finish it before summer is over). I've got the faceplate 99% finished off and I will be moving onward to the rest of the bucket. Like last time, I made a video document the build so I hope you guys watch it and enjoy it!



And here's a breakdown for those that would rather skim through it -

Priming the Faceplate:
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Primed:
VisxD6P.png


Sanded:
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Primed again:
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Sanded again:
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Spot Putty Applied:
FytSlKe.png


Spot putty sanded:
vQ5sfxZ.png


And final priming!
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The helmet as it sits now:
zvLPHyh.png


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eEvIfUN.png


R8mmkxX.png




I do know that with the recent photobucket TOS change, I lost all my original images. I will do my best to get them back, however they mostly were on the Mark 3 build that I originally started and now I've moved onto the Mark 42. I will still try to get them back asap though!
 

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Re: MF's Iron Man Helmet Build - 3D Printed Mark 42

Made some more progress on the Mark 42 Helmet! It's definitely coming along super well. Hopefully it'll be done in the next coming weeks!

I'll try to post some screen grabs later on too for those that would prefer pictures instead of watching the video!


First thing done was get rid of the old jaw since it was a pretty low quality print and would've taken a lot of time to surface properly
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New jaw
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Glued on
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Some Braces added
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Cracks in need of filling
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Filling
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Sanded and Primed
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Some alignment issues
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Filling
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Sanded down and additional layers of Bondo applied
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Getting there!
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Heyo guys, just wanted to give a bit of an update. Not much... but some progress has been made! Ears are attached and looking good. At this point, all that's left is sanding down the remaining layer lines and making sure some grooves and other pieces line up, but that's not too much! Hopefully it'll be done before the year is over.

VgGJtN5.jpg


IiPiFpi.jpg


yLQGJm3.jpg


ex6L9ts.jpg


And here's a pic with his brother from another universe :)
xQyYSfq.jpg
 
After over two years of working on this, the helmet is finally done. I'm so incredibly happy with how it turned out. Just like before, I have a video about what I've done since the last post that overs all the steps I took to get it here, and if you can't spare 20 minutes there's some screen grabs too!



Sanding down the layer lines on the jaw
xSSbJ0E.png


Glazing and Spot putty spread over the helmet
MDOBbrM.png


After being sanded down, the whole thing was given a coat of filler primer
lnVVmUR.png


First look at it together with the bodywork all done
7FiYrw5.png


First coat of paint
sjqCyYT.png


Painting the chin after masking
suf1PLF.png


Nice
E20uPdr.png


Painting the back
nKgQLBG.png


Also nice
USPq4az.png


Painting the faceplate
EcpllLV.png


Damn, I'm happy with this
ibxY1C1.png


Handing painting the cheeks with acrylic paint
HR73qTr.png


Black wash for grime and darkening of grooves
0cG9dDi.png


Clear coating all the parts
BGtvyqW.png


All dry
6SOPpip.png


First test fit!
YJ5eVTi.png


Eye construction, white cloth, clear plastic from product packaging, and 1mm craft foam
G6szf8y.png


All super glued together
clXe6Hl.png


One LED for each eye, shining from the middle out
kL2wF5B.png


Evenly diffused
G80JO2a.png


Hinge design
Tud1UJL.png


Mid Action
SvFRMya.png


Arduino Pro Micro
KSFx1sg.png


Straps that hold the back panel on
FV0oDip.png


Finished!
wm11fzl.png


Finished back
IcKpIG0.png


Finished Open
pDkLkks.png


Wearing the thing
bop3XRG.png


Closed
8j1TbXF.png




I hope you all of enjoyed my progress on this thing. This is the first Iron Man bucket that I have ever finished, and I'm really happy with how it turned out. If there's any questions, feel free to ask!
 
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I'm so torn on the video. On the one hand, it felt like it took too long to get to the build. On the other... I REALLY WANT TO KNOW WHAT'S WITH THE MYSTERY!

Looks good though! You've certainly got it opening the perfect amount.
 
I'm so torn on the video. On the one hand, it felt like it took too long to get to the build. On the other... I REALLY WANT TO KNOW WHAT'S WITH THE MYSTERY!

Looks good though! You've certainly got it opening the perfect amount.

I guess you could say it's perfectly balanced, as all things should be. But Thank you! The mechanism was what I was most worried about, but I think it came out pretty well.
 
I guess you could say it's perfectly balanced, as all things should be. But Thank you! The mechanism was what I was most worried about, but I think it came out pretty well.

Hey, could I buy the hinge files from you? They have a good range of motion. Please let me know
 
Hey, could I buy the hinge files from you? They have a good range of motion. Please let me know

Absolutely not. Why on Earth would you think you can buy them from me when I'll just give them to you :)

Hinge Files

I hope they can be of use! I have a text document explaining the parts. That, along with the pictures I posted of the inside, should be enough to help get you where you need to be.
 
Absolutely not. Why on Earth would you think you can buy them from me when I'll just give them to you :)

Hinge Files

I hope they can be of use! I have a text document explaining the parts. That, along with the pictures I posted of the inside, should be enough to help get you where you need to be.

Wow, thanks a bunch! I'll be sure to credit you when I complete my build. :)
 
That's awesome work! I'm currently building my pepakura mark 7 suit.. (first time builder)

The great goal in my head is always going to be motorization .. Your great files will get me one step closer! I've seen nothing but threads on the programming part, but none about the mechanical part!
Thanks!

A materials list would be amazing too!
 
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