Iron Man MK 6 foam armor PROGRESS PICS ADDED

**Immortal Goat** · May 6, 2012

Hello again, RPF! I am starting a new costume project, an Iron Man MK 6 movie suit using EVA foam floor mats. I have the pepakura files, provided by Stealth on his YouTube channel (thank you, Stealth, as well as a big thank you to the original creator of the files), and I have begun cutting the pieces out. My foam mats are about half an inch thick which seems kind of thick to me, but it's all I could find in stores near me.

Once I finish the foam build, I plan on coating the whole thing with resin, so it has a nice hard shell, and won't deteriorate the way most foam suits seem to.

Since I have just started, and this is my first foam project, any input would be welcome! Pics coming soon. Thanks!

**RPF Support**

**Kevin Gossett** · May 6, 2012

You will need to seal the foam before coating it. PVA/wood glue is the most popular way to seal. Three or four coats should do the trick, then you can move on to the outer coating

**Finhead** · May 6, 2012

No not correct. If your using smooth on 65D you just use it no need to seal it, that's what the resin is already doing.

**Kevin Gossett** · May 6, 2012

I stand corrected. I was under the impression the foam still needed to be sealed

**Immortal Goat** · May 6, 2012

Good info. Thanks. Any recommended brand of resin?

**Berserk** · May 6, 2012

Finhead said:

No not correct. If your using smooth on 65D you just use it no need to seal it, that's what the resin is already doing.

Re-read Finhead message, he tells you right there what to use

**Immortal Goat** · May 7, 2012

Ah, I thought that was a type, not necessarily the brand. Thanks for clearing that up

**Finhead** · May 7, 2012

Kevin Gossett said:

I stand corrected. I was under the impression the foam still needed to be sealed

Sorry you may be right, just pointing around now that I can log onto the site with my pc. XRobot seals his off with the PVA first. In any test I have done with the resin I have not used any sealer on the foam and it worked fine from what I can tell. So I guess I would advise to test a small piece first see how it goes and go form there.

**kopairnik** · May 7, 2012

I'm not really used to those forums and I don't know if it's ok, but I'm in the same position as Immortal Goat. Since I'm just starting the same project, is there any part of the suit that would be easier to build, you know to get me started.

**Finhead** · May 7, 2012

If it were me starting out again I would start with a bicep or gauntlet first test size and get the feel for it. If it's the wrong scale or whatever not a huge waste of time or material.

kopairnik said:

I'm not really used to those forums and I don't know if it's ok, but I'm in the same position as Immortal Goat. Since I'm just starting the same project, is there any part of the suit that would be easier to build, you know to get me started.

**bleahhh** · May 7, 2012

kopairnik said:

I'm not really used to those forums and I don't know if it's ok, but I'm in the same position as Immortal Goat. Since I'm just starting the same project, is there any part of the suit that would be easier to build, you know to get me started.

Not my thread But just wanting To help, try te chest piece
As the pcs are rather large and straight forward

**Immortal Goat** · May 7, 2012

I'm working on the chest piece first, but I haven't glued anything yet. Still cutting pieces out, but I'm already liking this method way more than making it out of paper. Pics soon.

**Onephattsi2** · May 7, 2012

im also i first timer... i started out with a forearm... it taught me a lot for sure....

kopairnik said:

I'm not really used to those forums and I don't know if it's ok, but I'm in the same position as Immortal Goat. Since I'm just starting the same project, is there any part of the suit that would be easier to build, you know to get me started.

**Immortal Goat** · May 8, 2012

Here's what I have of the chest so far. The glue is a little messy around the seams, but since I'm going to put a shell of resin over this, I'm not worried.

**ValTroX** · May 8, 2012

Yo seem to have done a good job, I'm also trying my first foam project(and project overall). My angle cuts aren't going so well

. I just ordered a mat cutter, as suggested by Stealth to try to get started with my MK7 armor

.

**Immortal Goat** · May 9, 2012

Couple shots of the completed chest, I'll have the back piece done later tonight, pics probably tomorrow.

**Immortal Goat** · May 10, 2012

Shot of the back piece. Some of the corners aren't very clean, so I'm going to use modeling clay to sharpen them before I put the resin on. Also, the thickness of foam I have is a little thick for the rest of the armor. Anybody know where I can find 1/4 inch foam online or in stores?

**CaptainVermont** · May 10, 2012

Check craft stores? It will come in colors, but 1/4 is approximately 6mm

**Immortal Goat** · May 10, 2012

Thanks for the tip

**payton paison** · May 10, 2012

I found Best Step 1/4 EVA foam at Sears.

**Immortal Goat** · May 12, 2012

Shots of me wearing the pieces I completed so far. Found thinner foam sheets (6 mm) and I'm working on the biceps right now.

**Immortal Goat** · May 15, 2012

Bumping with progress. Finished the biceps and the gauntlets, working on helmet now. I will have pictures in the next couple of days.

**Nahatma** · Jun 7, 2012

looking good, did you re-sized the templates?

**nestor300** · Jan 30, 2013

Hello,
just wanted to say that its looking pretty good so far and i was wondering if you re-sized the templates? im just asking because when i try to re size them the a lot of extra parts appear

Iron Man MK 6 foam armor PROGRESS PICS ADDED

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