Sandbagger's Iron Man builds - Now in STEEL.

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By the way, for those who want to save a bit of money, instead of buying a spatula, I just cut my own from the side of an empty plastic milk carton.
 
Second layer of body-filler sanded and shaped. One coat of dark primer applied. Once dry, a light sand all over will reveal all the low spots for filling in the next layer.
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Each layer of body-filler and subsequent sand makes it rounder and more symmetrical.
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Primer sanded back to reveal low spots. Ready for final (hopefully) coat of body filler to complete shaping and smoothing.

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I used an empty gift card myself ha, but nice work, sanding is a real pain...

Worth it though....

Yeah I know, they are all starting to look the same. This is hopefully the third and final layer of body-filler, curing overnight and ready for final sanding tomorrow. Then the detailing starts and it really starts to look the part!

Sorry, this is a bit of a blurry one. Stuck with only a crappy phone-camera today.
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Home from work - Too wet to build the observatory. To light to go inside the house. (Wasted daylight) Started fine-sanding and trimming edges etc. Now back to wedding-photo processing!! Busy life!

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Third sanding and some detailing. Made the cut lines to separate the face-plate. Coated with etch primer to reveal rough spots for fill and finishing.

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More sanding, more filling, a little more detailing. Built up the bottom lip a bit. Cut in a couple of join-lines. Primed again - it helps locate rough patches.

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1.Building up the bottom lip and correcting some distortion caused by excessive sanding on one side of the chin. Starting to shape the crown recess and tidying the eye edges.
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2. Added a little too much hardener to the mix, causing it to go off VERY quickly! Goes lumpy and gets very hard to work, spread and smooth. Will go over it with a thinner mix after it cures.
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3. Looking more symmetrical. Time to sand it again.
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1. Shaping the chin and bottom lip. Cutting in seams.
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2. Chin starting to shape up and look more tough, rigid and tech.
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3. Ready for yet another sand.
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4. Lookin cool.
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1. Seperated the face-plate and gave it a trim and tidy on the edges and inside. First spray of chrome to get a bit of an idea. More sanding on the outside to be done, with each coat getting smoother.
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2. Faceplate back on. Contrast shot.
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Looking good buddy, I'm thinking about doing a pep ironman helmet now I've finished my foam helmet.
 
Found a nice fine woven fibreglass cloth in Bunnings for $17. Much better than the chopped-strand mat.
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Comparison between chopped strand fibreglass mat and woven fibreglass cloth.
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The finer cloth is easier to lay and cut to shape and size.
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Resin applied to fibreglass cloth on the inside of the faceplate. Edges will be trimmed after curing overnight.
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Fibreglass cloth and resin applied to layer the inside of the helmet. Edges will be trimmed after it has cured overnight.
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Looks great. Good choice going with cloth instead of mat.

Yeah, it's so much easier to work with!

1. Reinforcing the inside with fibreglass cloth and resin.
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2. Before I trim the cured fibreglass edges off, a little filler to finish off shaping the helmet recess.
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3. Got a curve on the cheek I'm not happy with. It's a little too smooth and round, so I've built it up a little to reshape it to be more angular and with a sharper corner.
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4. Faceplate has had it's last application of bog. Very fine except on the cheek corners and a small flat spot on the top left forehead.
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5. Scruffy lookin' Tony Stark.
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1. The weakest part of the helmet is the recess at the top-centre that centres the faceplate. I've already cracked it twice while sanding it. Solution - a piece of scrap brass plate.
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2. Bent the brass plate to conform with the helmet contours.
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3. laying fibreglass mat over the brass plate.
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4 & 5. Fibreglass mat over brass plate resined and curing.
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6. Shinier and shinier!
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7. Faceplate off.
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8. Faceplate on.
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I tried the black helmet with chrome faceplate, but the black hides all the cut lines of the helmet. I am rethinking the colour scheme.
 
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