Iron Man By Design Build (NEED 3D HELP)

Greetings RPF,
I've been here for a little while and lately all of your work has been inspiring me to get something actually completed.

I'm becoming a real life superhero (there was an HBO documentary about them if you're interested in finding out more), and my theme is essentially "middle class Iron Man". While coming up with a design, I came across the cover of "Iron Man By Design" #1, and I immediately feel in love with it.


Being the amateur I am, I didn't exactly know where to start, but from what builds I've started (War Machine for a friend, Magneto helmet, HEV suit) peps are just the easiest thing to go with, at least for now.
I requested assistance from the 3D modelling forum on 4chan, and lo and behold, they delivered:


Only one slight problem, they did it in zbrush, which is WAY too high poly for my needs, so if anyone out there could perhaps create a low poly cage, or just decimate while making sure it maintains the right dimensions, it be GREATLY appreciated. The model can be downloaded here.


But aside from the request about the model, this thread will also be showing off the WIP and completed build, as well as showing off the actual armoring/tech I'll be building into my suit.

leaving aside all the pros and cons for this whole real live super hero stuff, im pretty sure this is a veeeery unpractical costume for it

The costume isn't what I'm wearing from that, just the helmet.
And real life superhero work is basically just walking around in a costume helping whoever and however you can. Someone needs help pushing a car, you go and help, someone is attempting to drive drunk from a bar, call a cab for them.
It's essentially Neighborhood Watch 2.0, if there's a crime happening, record it on video and report it, ONLY step in if someone's life is on the line.

And yes, that one is impractical.
My suit is going to be a EVA foam Iron Man Mark IV with some tweaks, then given a layer of truck bed liner for minor knife proofing, which a conceilable vest underneath and tasers built into the hands (with an on/off switch, of course).

Someone over on the 405th helped me with the model, though it's not exactly detailed, it's at 6000 polys, which is much easier for pepakura to run.

Took a few minutes in that, made a quick EVA foam pattern out of it, and here's where it's at now:

good luck

keep us updated on pics

most importantly...dont get hurt

would you be willing to share the EVA pdo?

do you mind if I post up a pdo? for foam?

Not at all, chances are I'll be making a second version at some point, so I'd appreciate it.
Would also love to see anyone else make it too.

I appreciate your concern. The plan is get something like a ski helmet and build on top of it, I mainly just want to do the faceplate part via shapeways.
I'm also experimenting currently on how I can use bedliner in molds or spray it onto a foam costume to add minor knifeproofing.

*phew*

thanks for letting me know man

No worries. Besides, I'm going as tactical as possible, just want to also show off what I build, since I do LOVE to build.
And always safety first, never patrol alone, carry a cell and camera, be vigilant.

Also, have you ever tried truck bedliner material to coat an EVA suit build? I'm trying to find anyone with a little knowledge before I invest in testing, since I'm practically working with a negative budget already.

Ah, you see, the EVA foam is mostly just to get the shape, it's easy to make and looks good. The bedliner isn't just your regular plastic, this is STRONG stuff. And I wasn't planning on covering the entire suit with it, just areas that are likely to gain high impact or possibly a glancing slice with a blade. I want the foam underneath for comfort, even if the chest has the liner coated on the outside, having the inside still be eva foam makes it much more comfortable to wear. Plus, when bed liner is applied, it maintains the shape it's sprayed in, so, if I do a couple coats on the outside of the chest or forearms, even if I take a tumble there won't be any bends or cracks in the plastic.

Johnnymuffintop said:

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Ah, you see, the EVA foam is mostly just to get the shape, it's easy to make and looks good. The bedliner isn't just your regular plastic, this is STRONG stuff. And I wasn't planning on covering the entire suit with it, just areas that are likely to gain high impact or possibly a glancing slice with a blade. I want the foam underneath for comfort, even if the chest has the liner coated on the outside, having the inside still be eva foam makes it much more comfortable to wear. Plus, when bed liner is applied, it maintains the shape it's sprayed in, so, if I do a couple coats on the outside of the chest or forearms, even if I take a tumble there won't be any bends or cracks in the plastic.

I misunderstood... So, you're talking about putting plastic pieces on the OUTSIDE of a foam costume.

If that's the case, the issue I see (purely from the costuming side of things) is how much wear-and-tear you will be pushing on your foam costume. Even the thickest of the EVA foam is not really designed for any stress more than a minor 'tumble.' Any more than that and you'll likely rip the foam (which would nullify it as effective armor of any kind).

I'm with STEALTH on this one. If you're looking for protection, find something designed for that. If you want to build a great looking costume that's easy to wear, EVA foam is a great way to go.

Combining the two will likely result in both an ineffective piece of armor, as well as failing to look very cool.

We shall see.
Gonna document my tests, if lo and behold it works out, you guys will be the first to know.

Also, I know EVA foam isn't exactly strong, but that's why I'm doing essentially this: Glass Bottle Impossible to Break by Universal Global Coatings - YouTube

This is like... "Iron-BORG" or something.

Is that a Steam Engine on his back???