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Hey everyone, let's make Ironman's helmet out of cardboard! I've built version number 8 of this helmet and have the whole suit made from cardboard (check the picture). Let's start our build! First, download Pepakura from here. Then, get the helmet template (Ironman's Helmet mark 42.pdo) and open it with Pepakura. Measure the height of your
head from the top of your forehead to under your chin. Click on 2D Menu → Change Scale → Set Scale and enter the number you find plus 1.5cm, for example, if you find 25.5cm, that's (25.5+1.5=27) in mm or 270mm. Next, adjust the template parts by selecting and dragging them to the center of the page so they don't cross the lines! Then, click on
File Menu → Print or (Ctrl+P), select your printer, and click OK. You'll get eight papers, with a note saying "Right Side" on two of them, which means those parts are only on one side of the helmet and you need to make a copy. Now, let's start working on the helmet! Tools needed: 1. Cardboard box 2. Template 3. Glue gun and hot glue 4. Glue stick 5.
Scissors 6. Cutter 7. Lighter 8. Pen or pencil 9. Ruler 10. PVA glue To make the eyes light (optional): 1. 6 LEDs (I'm using a 3V LED) 2. Prototype board 3. Solder 4. Soldering iron 5. Some wires 6. AA battery holder with a switch (I took it from an old toy) 7. White piece of cardboard 8. White piece of plastic (I cut it off from a bottle) Note: Keep the
template open on your PC. (Cut to the main article) Page 7: Draw a line between points of parts (see photo). Cut excess following the line. Place glue stick near point of paper 8 for gluing paper 7 on it. Ensure ends of piece connect on both pages. Cut pieces, glue them on cardboard, then cut whole piece. We're almost there! I'll start with faceplate
pieces. Cut a square piece of cardboard. Use hot glue to attach mid-forehead piece in the middle (see photo). Add side pieces, leaving 1mm space for details. Repeat for other side. Follow template for gluing pieces together. It's easy; just be patient. Assemble helmet: 1. Mix PVA glue with water in a plastic cup (75% PVA, 25% water). 2. Brush mixture
all over the helmet. 3. Let it dry, then add another layer of PVA glue and a little water. 4. Let it dry again. Eye details: 1. Place paper behind eye, trace shape, cut out, and place on plastic sheet. 2. Cut excess plastic following lines drawn earlier. 3. Round edges, place on board, trace round shape, remove excess. LED assembly: 1. Place LEDs in board,
align pins (cathode-cathode, anode-anode), solder together in parallel. 2. Solder two wires to ends of last LED. 3. Glue plastic piece onto board, creating a shield around LEDs. 4. Cut paper, glue on top of plastic to cover LEDs. 5. Repeat for other eye. Connect eyes and test them. Then: 1. Solder file to wire on eyes, cover with tape. 2. Solder end of file
to switch and GND on battery holder. 3. Test it – WELL DONE! Paint the helmet: 1. Paint faceplate with gold spray can. 2. Let it dry, paint again. 3. Cover faceplate, upper lip, and upper piece of jaw with tape. 4. Paint entire helmet with red spray can. 5. Let it dry completely, then remove tape carefully. Back piece: Cut back piece carefully using
cutter. Attach stripe (from old bag) to back of helmet using hot glue. Allow it to be openable. Final assembly: 1. Glue eyes in place, leaving a small gap between under-lights and helmet eyes. 2. Enjoy your completed project! Thank you for following this instructable! If you have any questions or comments, please let me know below.
