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 Rank: Elite        Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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My son (who is 9 soon) said to me that would'nt it be cool if I could make him an IronMan Helmet...   So I did some research on MeTube and found some very interesting tutorials about people who make these for fun and even a living... So after watching a few and downloading the PEPAKURA Viewer and some of the free files on offer I decided to have a go and this is what will be a little build diary of what hopefully will be WarMachines (IronMan) Helmet in 1/1 scale. Below are links to anyone else who fancies to give this a go!! It's great fun and gives a break from the norm.. Tools you will need are PRINTER 240 GSM A4 Card Sharp Knives (X-acto) A good large Cutting Matt CA Glue or any other quick bond card/paper glue and finally...Patience Links.... PEPAKURA VIEWERYouTube TUTORIALSHARDENING AND READY FOR FILLINGHere is the start of mine.. Warthog attached the following image(s):
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 Rank: Pro Groups: Joined: 24/08/2009 Posts: 48,827 Points: -13,348
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An interesting project Spencer!!  
Your son is going to be soooo proud of his dad when it's finished - well done you!! 
Kev
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Hi Warhog, Check this out for a bit of inspiration. Yesterday i was at a rock festival in Manchester and as it was May the 4th it was Star Wars themed (May the 4th be with you lol) anyhow met this lot and they had made their own costumes and weapons serous stuff - god luck with the mask excuse the picks of me and my daughters     “Whenever you find yourself on the side of the majority, it is time to pause and reflect.”
-Mark Twain
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Jase.. Theres a Group/Forum who make all the costumes and stuff for Festivals and Shows and especially in the US it's big stuff and some even go to the extent of motorising a lot of their costumes... Very impressive some of it and a cost effective way to get a full StormTrooper outfit..
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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My fingers Hurt!!! A small update as this takes time as have to cut out every part (15 sheets) then fold and glue!! Warthog attached the following image(s):
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Rank: Pro Groups: Joined: 24/08/2009 Posts: 48,827 Points: -13,348
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Looks like a lot of work Spencer, though I'm sure with your skills it will be worth it in the end and your son will love it!!
Kev
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Rank: Pro  Groups: Registered
Joined: 09/08/2011 Posts: 386 Points: 1,129 Location: Hertfordshire
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Pepakura is a great programme!! I used it a few years ago when I made my replica Daft Punk helmets I fully feel your finger pain, some of the small tabs can be a right b!tc# Something I did differently though to make the job a little easier is rather than try the make the helmet in 1 go, I cut it down the middle making 2 halves Ment it was a lot easier putting all the pieces together! couple of pics to show you what I mean Might be worth considering, if you find it a little fiddly!
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Thats Pretty cool mate!! What did you use for hardener in the end or recomend? BTW not forgotten about your nose 
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Rank: Pro Groups: Registered
Joined: 09/08/2011 Posts: 386 Points: 1,129 Location: Hertfordshire
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Cheers I used fastglas resin out of halfords Applied it to each half to harden, cut off the excees and joined them together, then resined again to complete 2 as 1 Then a couple of layers of faithful filler That's as far as I've got with this, needs sanding, filling sanding filling sanding etc etc Some of the guys of the daft club have literally spent months sanding and filling just to get it right and smooth! Yeah I've not touched the brawn in an absolute age, need to get back on it really  wife and sprog are off to scotland again soon, might have to knock it out of the park while they're away So no rush mate, as and when you get a chance to have a think
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