So I'm working on Iron Man again, this time for realzies. What with the movie comig out and all, I'm hyper-motivated and I have a little bit to show for it. One of my biggest embarassments last year was my helmet. It just looked rough. I made it out of papier mache and laquer, and while it was a triumph of papier mache engineering, it wasn't what you'd call beautiful.
Anywho, this year I got an early start and found a wonder material- sintra. It's a 1/8" sheet plastic deforms at about 140 degrees, and hardens in seconds. So I can make nearly anything I want with a heat gun and a pocketful of dreams.
The following is my roommate Jason modeling the helmet:
Of course, these are just the major components... there's a lot to go. But I figure it's far enough along that you can get the idea.