Iron Man Mk. III helmet commission - Now Finished!!!

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vshore100

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Hello 405thers. I was recently commissioned to make an Iron Man Mk. III helmet and I wanted to share my progress with you. The client didn't want the most detailed helmet in the world, he just wanted a nice helmet to display in his man cave. So he and I settled on the IronMansmallchin helmet file by Samuray. As I said, it's not the most detailed pep file out there, but it is a nice helmet over all.

I have been working on this for about three weeks off and on. It's starting to come together nicely. Here it is after two coats of resin on the outside and two coats of Rondo on the inside. You can also see that I have sanded down the seams with the sanding bit and a flex shaft on the dremel.
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I then started applying filler to the top of the helmet and sanding with 80 grit to knock it down to an even layer.
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More sanding and filling.
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Here it is after it's first coat of primer.
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Yet more sanding and filling, but this time I switched to 180 grit.
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Second coat of primer. You can see it starting to smooth out pretty good now.
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Now onto the spot putty and 320 grit.
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Continued on next post...
 

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Normally this file is split in two sections, the chin/ faceplate, and the back half of the helmet. This wouldn't work in our case because the opening still wasn't big enough to get my head in. (I used my head as a gauge. If it fits me, it'll fit him, lol.) So to remedy this, I drilled four small holes in the helmet, two on each side, and proceeded to cut the back of the helmet off using and exacto saw blade.

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Coat #3 of primer...
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Once all the sanding is done, I'll go in and carve all the detail lines for the faceplate, etc. back in to give it the appearance of being a separate piece. Also, the back will be attached with magnets for quick removal and attachment. There's still more sanding and filling to be done, but I'm pleased with how it's turning out. I'm trying to move this along so can get back to the CQB armor....again!
Anyway...thanks so much for stopping by and taking a look at what's going on. Until next time..Keep building guys and gals! :D
 

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Is this the same file as the Samuray easy helmet?

You're certainly getting a smooth finish on this commission, and it's nice to see another Iron man build.
 
I'm not sure if it's the same or not. Thanks for the kind words though. Much appreciated! :D
 
Update!

It's time to carve the detail lines! I started by getting some measurements of the pep model using the measurement tool in Pepakura Designer. I then transferred those measurements over to the helmet and proceeded to mark off the lines with tape and a thin sharpie.
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I started to carve the lines freehand, which is tricky, but doable. But then I thought, why not use the tape as a guide. So I did. I laid tape down on both sides of the sharpie line. This gave me a small valley to run the cut down piece of a hacksaw blade through and ensured I had a nice straight line every time.
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Next up I'll be mounting the tabs and the magnets to attach the back of the helmet to the main section. Then it's onto mocking up the eyes, then onto paint! :D
 

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Looking great....good thinking on using the measurement tool in P.D. This is shaping up very nicely, good job buddy!

-Matt
 
Great to see another project V, its looking awesome!
I have to know though, where did you find those exacto saw blades?! those would be so useful lol.
 
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Great to see another project V, its looking awesome!
I have to know though, where did you find those exacto saw blades?! those would be so useful lol.

Thanks M! I actually bought them at Walmart. They came in very handy. :):
 
Looking great....good thinking on using the measurement tool in P.D. This is shaping up very nicely, good job buddy!

-Matt
I completely missed your quote Matt! Thanks for the kind words. Yeah, the measuring tool is very helpful.

We have paint!!! Here's the cherry red sprayed over the entire helmet. It's deeper than what the pic shows.
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Then the gold. Once again, the gold is deeper than what it shows here. The camera on my RAZR is acting funny lately.
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Here are the light boxes that I scratch built. I used some pre-made led lights and 1/8th" plastic for the lenses. The rear portion of the boxes were made out of 1/16" plastic sheet. I heated the lense with the heat gun, pressed them into the eye holes to get the shape, then built the rest of the box to fit. The lights were hot glued in place then taped off and sprayed flat black. They aren't too bright, but I didn't want something that was over-powering.
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The darker edges won't be seen, that's where they get glued into the helmet. Once the helmet is cleared and dried, I'll get them fitted along with some padding, then we'll call this done and get it over to it's new owner. Luckily for me he lives on the next street over, lol. :D
 

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Thanks M! I actually bought them at Walmart. They came in very handy. :):

No kidding!? well i know where im going after work today lol.


New progress pics look great too by the way. At first i was going to ask how the guys is supposed to see with the helmet on, but i remembered he wanted it for his man-cave as a show off. Unless he is actually going to wear it and be able to see out of it then i must know how lol
 
No kidding!? well i know where im going after work today lol.


New progress pics look great too by the way. At first i was going to ask how the guys is supposed to see with the helmet on, but i remembered he wanted it for his man-cave as a show off. Unless he is actually going to wear it and be able to see out of it then i must know how lol

Thanks again M! It is going to be a wearable display in case he ever has the urge to do so.

It's finished!!! I was able to get it cleared, get the padding in, and get the lights installed last night.

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Over all, I really pleased with how it turned out. Let me know what you think. The feedback is always appreciated! :D
 

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That's some beautiful work! I can only hope that my Ironman build turns out like this. What lighting did you use for the eyes?
 
As I said before, very smooth work, and everything looks straight and true.

It's also nice to see a closed helmet.

Keep 'em coming.
 
Wow....very nice work!! Everything looks super clean. Good job buddy!

-Matt
Thanks very much Matt!

That's some beautiful work! I can only hope that my Ironman build turns out like this. What lighting did you use for the eyes?
I actually used a pre-made 10 count led light kit that I found at the Dollar General Market. they put out nice light and the it already had the battery box, etc. ready to go.

As I said before, very smooth work, and everything looks straight and true.

It's also nice to see a closed helmet.

Keep 'em coming.
Thanks Dorvack. I appreciate the comments. :D

I dropped the helmet off to it's new owner Friday evening and he was blown away by it. I surprised him with a helmet stand as well. It was a 12" x 12" stand with a square helmet pole for display. I putty coated the entire thing, sanded it smooth, sprayed it black, then used the same clear on it as I did on the helmet. It turned out great but I completely forgot to take pics of it. He was kind enough to take a few and send to me. :)
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I actually used a pre-made 10 count led light kit that I found at the Dollar General Market. they put out nice light and the it already had the battery box, etc. ready to go.


Oh wow, I may be looking for that. The light put out is greater than most I've seen!
Your work is an inspiration ;) Can't wait to start my own!
 
Oh wow, I may be looking for that. The light put out is greater than most I've seen!
Your work is an inspiration ;) Can't wait to start my own!

I'm really glad you are inspired Jay! I really look forward to seeing what you build, now go get started!!!:D
 
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