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Iron Man Helmet by JonsProjects Iron Man Helmet by JonsProjects
Hi guys and gals, we'll my latest project has been a bit of a hush hush until I revealed my blog 3 weeks ago.
So I've been working on an Iron Man helmet, from the movie.

I started off by making the helmet from card, using a Pepakura model. If you'd like the Pepakura model then check out the 405th.com forum and search for a Iron Man helmet made by Sharkhead.
Once constructued I then resined the outside and fiberglasses the inside. This makes it insanely strong.
I then dremelled out the face plate.
I then used lots of car body filler to mold the curves and detail. This is what takes up the time, and being a perfectionist means it takes even longer.
Once this is done I used multiple coats of primer to show off imperfections which I rectified.
Then paint and laquer to protect and I'm done.

The face plate comes off and is held on with magnets, but I'd like to install a hinge but haven't found anywhere in the UK to buy them.

If anyone has any questions then please leave a comment and I'll do my best to answer them.


Jonathan
Add a Comment:
 
:iconstrikeu:
StrikeU Featured By Owner May 31, 2013  Hobbyist Filmographer
You should Make me one!
Reply
:iconldy92:
LDY92 Featured By Owner Apr 16, 2013  Hobbyist General Artist
Hi, I might be making one of those after my final exam, so I've some question before making:
Did you bondo the exterior of the helmet or just resin it?
How much gsm of the paper did you use?

BTW, nice helmet!
Reply
:icontomtomh92:
Tomtomh92 Featured By Owner Apr 1, 2013
Do you cell it ?
Reply
:iconjeni-stark:
jeni-stark Featured By Owner Jul 17, 2012  Student General Artist
Awesome job! What kind of magnets did you use for the face plate?
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Jul 25, 2012
I used neodymium magnets on one side, and a thin metal plate on the other.
Reply
:iconblueai:
blueai Featured By Owner Jun 23, 2012
awesome...im about to start my iron man pepakura soon
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Jul 25, 2012
Good luck
Reply
:iconaura-shadow:
Aura-shadow Featured By Owner Jun 13, 2012  Student Digital Artist
Odd question, but is that Floam on your head mannequin? If so, why?
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Jun 15, 2012
The foam is attached to the helmet. So it's comfortable when I wear it.
Reply
:iconaura-shadow:
Aura-shadow Featured By Owner Jun 18, 2012  Student Digital Artist
Ahhhhh. I understand now. Thanks! :)
Reply
:iconbackseatgamers:
BackSeatGamers Featured By Owner May 15, 2012
now when you say fiberglassed the inside, what exactly do you mean, noone will ever tell me straight how the hell to use fiberglass mat and what not
Reply
:iconjonsprojects:
JonsProjects Featured By Owner May 17, 2012
You chop up some fiberglass mat and then apply it using polyester resin. You can get both at Halfords, there are lots of tutorials on Youtube for this.
Reply
:iconcastro91b:
Castro91b Featured By Owner Feb 16, 2011
how much do u sell them for???
Reply
:iconcastro91b:
Castro91b Featured By Owner Feb 16, 2011
how can i get one???
Reply
:iconfmhqbattousai:
FMHQBattousai Featured By Owner Dec 15, 2010  Hobbyist
Very nicely done! I'm about to start on the very same helmet (it will be my first Pepakura project) and have been looking around for inspiration. Well, it looks like I found it haha

Yours and Timecon's projects are awesome. I can't wait to start.
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Jan 28, 2011
Nice, let me know how you get on.
Reply
:iconclarts72:
Clarts72 Featured By Owner Nov 1, 2010  Hobbyist Digital Artist
please tell me about the "open/close" mechanism of the plate :D
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Nov 3, 2010
I don't currently have a hinge system. The faceplate is just sitting on top of the helmet in the pictures.
When attached it's held in place with magnets.
Reply
:iconclarts72:
Clarts72 Featured By Owner Nov 22, 2010  Hobbyist Digital Artist
errr okay .. i thought u have used "rail system" before
Reply
:iconzanruos:
zanruos Featured By Owner Jul 3, 2010
did u use the hinge system
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Jul 5, 2010
Nope, it's just sitting on top of the helmet in one of those pictures.
Reply
:iconzanruos:
zanruos Featured By Owner Jul 5, 2010
ah k i just had to ask
Reply
:iconcorystark:
CoryStark Featured By Owner May 20, 2010
are you making these to sell yet?
Reply
:iconjonsprojects:
JonsProjects Featured By Owner May 23, 2010
Yes I am, I'm just about to put up a Deviation to advertise the one I have for sale.
Reply
:iconcorystark:
CoryStark Featured By Owner May 23, 2010
how much?
Reply
:iconskywalker1188:
skywalker1188 Featured By Owner May 7, 2010
that is brill!!!!! you must be very skilled!!
how much would you charge for one?
Reply
:iconjonsprojects:
JonsProjects Featured By Owner May 11, 2010
Thank you very much
The price depends on the type, a straight cast is a lot cheaper but it does mean you will need to clean it up a bit, sand and paint it.
If you're truly interested send me a note for the prices.
Reply
:iconuratz-studios:
Uratz-Studios Featured By Owner May 2, 2010  Professional Artisan Crafter
if u make molds of this thing and selling the castings, pls let me know. Cuz I want it.
Reply
:iconjonsprojects:
JonsProjects Featured By Owner May 3, 2010
I am selling castings.
But I wasn't planning on selling outside the UK because of shipping charges.

If you can find a decent courier between UK and your country of residence then we can talk.
Reply
:iconuratz-studios:
Uratz-Studios Featured By Owner May 3, 2010  Professional Artisan Crafter
Does your country have EMS, or your local post that offer overseas Express shipping? Maybe u can check at the post office. I'm sure there's a pretty reasonable service with tracking that's not FedEx or DHl (unless out of choices)
Reply
:iconjonsprojects:
JonsProjects Featured By Owner May 4, 2010
Here in the UK we use Royal Mail, I've checked their site and the only international service which has enough compensation is Parcel Force Worldwide at 66.19.
Check it for yourself:
[link]
The package will be 1.5kg
Reply
:iconuratz-studios:
Uratz-Studios Featured By Owner May 4, 2010  Professional Artisan Crafter
Any other profile shots of this helmet? Whats the price tag of this baby?
Reply
:iconjonsprojects:
JonsProjects Featured By Owner May 11, 2010
I posted some pictures of the master along with the copy on this new forum
[link]
Check them out
Reply
:iconuratz-studios:
Uratz-Studios Featured By Owner May 11, 2010  Professional Artisan Crafter
nICE!
Reply
:iconwolverine1977:
Wolverine1977 Featured By Owner Feb 27, 2010
WOW - could you send me a copy of the pdo file I'd love to have a go at creating one of these
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Mar 24, 2010
Here's my post (I'm Jonny on 405th.com) on 405th.com where I've posted a link.

[link]
Reply
:iconblackmarkerstain:
blackmarkerstain Featured By Owner Feb 23, 2010
yeh if u could make me 1 for like $100-150 I'd buy 1, anything above that it'd be out of my price range, considering I'd have to pay us pricing and shipping, and being from cananda, but defeinatley interested and definatley a fav
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Mar 24, 2010
I'm only planning on selling them to UK/Europe based buyers.

Check out 405th.com forums as I'm sure there are Americans and Canadians on there who could sell you one.
Reply
:iconjamesmarsano:
JamesMarsano Featured By Owner Feb 15, 2010  Professional Digital Artist
have you seen dungbeetle's pep design? its very accurate. idk if the one he has is better than sharkshead. but check it out.
starx will finish the rest of the armor when the movie comes out. whats your username on the 405th?
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Mar 24, 2010
Yeah I've seen all of Dungbeetles versions, but I prefer Sharkheads.

I think it's more accurate and it doesn't have any openings.

I'm Jonny on 405th.com
I started on Dancin Fools chest and back but got the size wrong so now I'm back to nothing. Taking some time out, but I'll probably pick it up again.
Reply
:iconjamesmarsano:
JamesMarsano Featured By Owner Mar 24, 2010  Professional Digital Artist
nice helmet pics.
I don't really like the dungbeetles version either. can you by any chance send me the sharkshead helmet link?
yeah
i would do the same thing too.
how tall are you?
I'm 5'3 and I'm pretty slim do you think the torso would fit me?
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Mar 25, 2010
Take a look through 405th forums, you'll find all you need there.
Reply
:iconnekoflamealchemist:
NekoFlameAlchemist Featured By Owner Feb 11, 2010
This is truely amazing!
Nicely done :D
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Mar 24, 2010
Thanks :D
Reply
:iconnekoflamealchemist:
NekoFlameAlchemist Featured By Owner Mar 24, 2010
You're welcome - I really envy your talent! :D
Reply
:icontimdrakerobin:
TimDrakeRobin Featured By Owner Dec 28, 2009
Thats very good work. If your interested in the rest of the armor
let me know.
Reply
:iconjonsprojects:
JonsProjects Featured By Owner Dec 31, 2009
Hey Tim, I'm tempted to make the rest of the armor, everyone I show the helm to say I should make it.

I browse 405th and section-sixteen on a daily basis so I'm always up to date with the latest Peps. Juice on 405th forums recently released a very good war machine Pep, I'm very tempted to make it :D
I'm Jonny on 405th and Section-sixteen.
Reply
:icontimdrakerobin:
TimDrakeRobin Featured By Owner Dec 31, 2009
oh ok I am on Section-Sixteen as StarkElectronics, not on the 405th though.
Reply
:iconstargazer-gemini:
Stargazer-Gemini Featured By Owner Dec 11, 2009  Student General Artist
That... is impressive.
You deserve many more views.
Reply
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