msleeper said:
Hate to say it, but the trick is using thinner foam. Really the 1/2" stuff is not ideal for Iron Man / War Machine builds at all. I've trashed 2 chest pieces, two arms, a shin, and a bunch of cut-out-but-not-assembled foam because I used 1/2" and it was fighting me the whole way. Don't get me wrong, you did a great job with it given the material. But next time you make a suit, do yourself and your wallet a favor and buy thinner material. Best Step makes 1/4" interlocking tiles, you get 6 to a pack instead of 4.