Iron Man Helmet: Foam Vs Cardboard

[sfreak77]

Hey Everyone.

I've been lurking around the site for almost a year now and after 7 different builds finally have a build worth posting pics of.
I tried EVA foam, camping mats and cardboard all the popular suggestions. I had a few "ehh kinda" builds but finally came out withe two good base builds.
One in Foam (Left) the other in cardboard (Right),

A few things to explain.
The Foam one is 10% larger than the cardboard (164mm Vs 151mm) basically size medium and large.
I did this for two reasons, the foam fits with room for inner padding to make a motorcycle helmet.
The cardboard is a nice flush fit on my head with just enough room in the top for a cooling fan so i don't fog up
Both are a long way from being done but are ready for resin and body work.

I will post more pics and info when i have a chance.

 

[JPH]

both are nice, the foam one I likee betteree

 

[stigmorgan]

Looks good, interested to see how you make up the motorcycle helmet.

 

[Kevin Gossett]

Wait... You're going to make a motorcycle helmet out of foam? I'm hoping it's not for actual riding...

 

[sfreak77]

Wait... You're going to make a motorcycle helmet out of foam? I'm hoping it's not for actual riding...

Heck no.
I plan to use it to make a mold.
I'm planning to cast the outer detail layer in fiberglass resin backed with heavy glass mat.
I will be finish lining it with 10 mm Eva.
I used my old motorcycle helmet to get a rough idea of the thickness required.
I live in NY and my county has no helmet law so it won't need dot certificate.
It will mostly be for show tho.

 

[stigmorgan]

Should look awesome. Cant wait to see it.

 

[sfreak77]

I couldn't sleep last night so I banged out another helmet.

 

[stigmorgan]

Sweet. Fast work, takes me at least a couple of days to build a helmet.

 

[sfreak77]

Sweet. Fast work, takes me at least a couple of days to build a helmet.

Took about 4 hrs.
I made master patterns during my first build.
So I just lay it out, trace, compress, cut and glue.
I really like the ability to shape a part before gluing it.
It really helps the details.

 

[sfreak77]

Making progress and started a custom helmet to help me get some creative ideas out.

 

[sfreak77]

View attachment 335511

 

[stigmorgan]

Looking great

 

[sfreak77]

 

[sfreak77]

Lots of pics of the build to come.
Just got carried away and haven't posted any.

 

[stigmorgan]

Dude that is Sweeeeeeeeeeeet

 

[stigmorgan]

been an age since last update, how did the motorcycle helmet turn out?