The glue helps to seal the foam and provide a smoother surface finish once the paint it applied. I did the paint test on scraps of regular foam and scraps which had been coated in Elmer’s White School Glue.
I didn't do any more work on the helmet itself but I bought and tried out some spray paint which I may use on the helmet. Once I get a bit more finished I'll post an update, which should be in another day or two. Eventually I want to cast a few helmets in aluminum.but we'll see how far I get. Then I will make a fiberglass cast of the helmet which will be fixed up further. I plan to fill the seams and other rough spots of this helmet with Bondo body filler. But unfortunately my heatgun broke.so I may have to use a hair dryer to finish the bends. The helmet still doesn't fit together perfectly, there is a bit more bending to do.
There was a lot of freehand and guessing angles based on the 3D Pepakura model and pictures from the internet. A heatgun was used to curve the foam to the shape needed. With all the pieces cut I began the process of hot glueing them together. I printed these pieces out and glued them to some 5mm craft foam. To the right is a screenshot of Pepakura viewer, it provides a 3D model of the project as well as the 2D pieces which create the model. For anyone that doesn't know, Pepakura is a really cool program which is often used for papercraft but which can be used for all kinds of other things. I started by downloading the Pepakura Viewer and Pepakura files for an entire Iron Man suit. So I really didn't take any pictures during the beginning part of the build. But I realized there were none on LMR, besides hardmouse's awesome Clone of IronMask. So I figured I would post my build.
You can find loads of Iron Man helmet and full suit builds all over the net. But be that as it may I decided that I would still post this, even though I'm not really doing anything unique here. So I know it's strange that my first project post on letsmakerobots isn't a robot.