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  1. JFcustom's Avatar
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    Jun 26, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #101

    bak9799 said: View Post
    I second this!!!!!!
    I'll be here soon...

    Last edited by JFcustom; Jun 26, 2012 at 9:23 PM.
  2. BobbyS95's Avatar
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    Jul 3, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #102

    I have an odd question for you.

    I'm assuming that the templates are scaled for yourself, so what is your height/weight. I'm wondering if I have to scale them or if it is close enough.
  3. teragon's Avatar
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    Jul 3, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #103

    If it helps, I have to scale it to 24 in general, some parts need a bit more tweaking but otherwise 24 works ok, a bit tight sometimes actually, but 25 is too much. It is usually set on 23 when you open the files.
    I'm a solid 6'1, just under 6'2 and average to large frame with 180 lbs.
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    Jul 14, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #104

    C'est ιnorme ce que tu as fait !!

    Nice work !!!
  5. JFcustom's Avatar
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    Jul 14, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #105

    I was passing by, I saw a light... I built.

    Around here almost everyone does better.
    Not so fast, I must concede, but much better.

    The worst is now that my children are on holydays, I have even no time enough to build fast anymore !
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    Jul 15, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #106

    Absolutely LOVE what you did and would like to make a suit myself. Im having troubles finding the right matting you used in the states though. Especially at the price shown in the link you posted 8(. ALl im finding is matting thats 15-20 dollars! What type of glue did you use to stick the foam together?
  7. JFcustom's Avatar
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    Jul 15, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #107

    It is the cheapest basical noname flexible hot glue I found, sold for something like 5$ a pound. You can see a part of the package on the very first pic.
    For this suit I used a wole pound.
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    Jul 15, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #108

    The fact that I can just download the rar is a huge help. I'm about 6' feet tall with the same build, do you think I'll have to resize anything?
  9. oraclemask's Avatar
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    Jul 15, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #109

    Halloween costume SORTED
  10. bak9799's Avatar
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    Jul 15, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #110

    willyw8y said: View Post
    Absolutely LOVE what you did and would like to make a suit myself. Im having troubles finding the right matting you used in the states though. Especially at the price shown in the link you posted 8(. ALl im finding is matting thats 15-20 dollars! What type of glue did you use to stick the foam together?


    Go to Yoga Mats, Exercise Mat, Polyethylene Foam, Yoga Mat, Exercise Mats and choose. 25inch or whichever size thickness you want. Just make sure your ordering Eva foam
  11. dArtagnan's Avatar
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    Jul 15, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #111

    Wow, that's awesome for such a fast build!
  12. Keyamon's Avatar
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    Jul 27, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #112

    Absolutely loving these tips and files!

    I'm planning to start building my own armor using these files next week, but I was wondering what I'd have to scale the files to, as I'm 170 cms tall, and I'm sure the suit won't fit me if I don't modify it first.
  13. Doomster's Avatar
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    Jul 31, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #113

    I was originally trying to do the Mark III, with other files. But school and stuff has gotten in the way. Your modified Robo3867 Mark IV files are awesome and will help a lot! Your tips are very helpful. I will definitely follow your thread.
  14. AH studio's Avatar
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    Aug 24, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #114

    Thank You from Brazil!!!
  15. askernas's Avatar
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    Dec 6, 2012 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #115

    Amazing build!
    I saw a guy this weekend with a foam Iron Man suit.

    No doubt made from or at least influenced by your build and files! =)

    Makes me wants to make my own..
  16. Join Date
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    Jan 10, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #116

    Fantastic work! I don't if anyone asked... but how much total did it cost you to build? Like a rough estimate.
  17. JFcustom's Avatar
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    Jan 10, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #117

    How much... well, hard to say since I already had everything but the foam and the red paint.

    But let's count (roughly from memory) in the case you have none of the prerequisite to start with :
    8 foam rolls 3€ each (I recommend 12 rolls to build cleaner and faster),
    4 spray paint 7€ each,
    1 bucket of Sikafill 50eur (but a bucket can do 15 suits...)
    1 regulated glue gun 45€ (a 7€ gun can go, it's what I used for this one)
    1 pack of glue sticks 12€
    1 cutter and blades 10€
    2 rolls of velcro tape 5€ each
    1 pack of 100 rotative junction clips 20€ (you'll need only a few of them)
    1 pack of 50 quick fastener clips 25€ (idem)
    1 led spot for the arc 3€
    and in a sense the most expensive : a lot of time spent while not doing anything else.
  18. Join Date
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    Feb 19, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #118

    Good work! I'm trying too but I think I'll not finish in time...
    I'm italian too :P
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    Feb 21, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #119

    Hey at first I want to tell you that I really admire your work. In 5 days you came out with a pretty nice suite. I only wonder how it would have been if only you had more time

    Now let's start with the questions! Domyos mats are quite cheap 3,50 euros here in Italy, I don't think I'll be able to find cheaper ones. You gave such a good tip you cannot imagine ...well....your tips are golden!

    Can I shape them with a hot gun or a hairdrier?
    Sikafill: do you think it works better than a common and cheap PVA glue+primer?
    Did you obtain a smooth surface after painting?
    Are they solid or can still bend (eg: sit with your suite on XD)

    After this experience would you change something in your workflow or materials?

    Greets
  20. JFcustom's Avatar
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    Feb 22, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #120

    brand said: View Post
    Can I shape them with a hot gun or a hairdrier?
    I can't say, I never tryed to. Up to now it has never been requiered.

    brand said: View Post
    Sikafill: do you think it works better than a common and cheap PVA glue+primer?
    In fact, a couple of days ago after a compatriot experienced some tests with this Domyos mats, I learned that you can apply some polymer resin directly onto this foam without any preliminary coating. It sticks perfectly well, the foam doesn't melt down at all and remains unspoiled.

    brand said: View Post
    Did you obtain a smooth surface after painting?
    No, it touches like something like leather, or soft wood. If I have had one more day I could have applied a coat of my acrylic flexible glossy varnish. That would have give a really smooth surfacing.

    brand said: View Post
    Are they solid or can still bend (eg: sit with your suite on XD)
    I can sit down with the suit. But if you sit several hours consιcutively, the foam will become thinner under your weight. Well I assume it will, I did a test putting a piece of foam under a chair leg all night long, I got the print of the leg tip on the foam.

    brand said: View Post
    After this experience would you change something in your workflow or materials?
    For a five days build (and 4 nights) ? no time enough to change anything ! I still was painting it the D-day at 8am to be ready at primary school for 10am.
  21. Join Date
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    Feb 22, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #121

    Thank you for your quick reply! May ask you the exact names of the products I should use to coat and pain my suite in the best way? I hope I'll be able to find the same products here in italy...in the worst case this would be the right chance to have a trip in France just after the border to buy them :P :P
  22. JFcustom's Avatar
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    Feb 22, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #122

    The rubber coating is branded "Sikafill", or "Fortix". More here : environmentally friendly / eco friendly resin/fiberglass?
    If you prefer resin, it's "SINTO polyester resin".
    For the paint, it's obviously the first comer of the desired color...
    About the foam you already know.
  23. Join Date
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    Feb 22, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #123

    JFcustom said: View Post
    The rubber coating is branded "Sikafill", or "Fortix". More here : environmentally friendly / eco friendly resin/fiberglass?
    If you prefer resin, it's "SINTO polyester resin".
    For the paint, it's obviously the first comer of the desired color...
    About the foam you already know.
    Thanks well, resin should give a better surface as you said so, maybe I'll choose that option if it won't crack too easily.
  24. JFcustom's Avatar
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    Feb 22, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #124

    I don't know if it'll be better. It all depends of what you expect, and how you plan to use your suit. All I can say is that Sinto resin will make it hard and, surprisingly, won't melt the foam down. I'm happy with my Fortix, I can apply it indoor, my suit doesn't hurt children who bump into me... I don't think I'll change it for some resin.

    AH studio said: View Post
    Thank You from Brazil!!!
    From what I read on the packaging export notice, this foam is also available in Brazil isn't it ?



    Last edited by JFcustom; Feb 22, 2013 at 2:17 PM.
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    Feb 27, 2013 - Re: Inexpensive 5 days built Foam Iron Man Mk IV #125

    Amazing work, that inspired me to try it. I have a quick question, though

    How big is the suit? I'd have to pack it for a 8h trip, and wouldn't want it ruined, obviously.

    Also, to answer one of YOUR () questions, I'm from Brazil, and can't find any stores that sells 6,5mm PE fitness mats.
    In fact, getting good EVA or PE foam for a reasonable price at small amounts seems ridiculosly difficult. The suppliers have minimum order quantities, the stores sells low-quality foam and charges your eye-ball for it. I'm seriously considering importing my foam :P
    Last edited by LGripp; Feb 27, 2013 at 3:06 PM.
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