Iron Man chest prosthesis

I've had this sculpt pending for a bit and will get started this weekend, and plan to have the first pull by late July.

The problem with having a wearable arc reactor is that often they are thick, or are too obviously an external object and not part of the chest. To fix that, I'm planning on creating a reusable prosthetic out of silicone to fit the standard size arc reactor (with a 3.5" diameter, as in ThrowingChicken's excellent kit).

In the movies, Robert Downey Jr's chest was actually latex that was layered up each time and then airbrushed:



I'm intending to make it a smaller piece that will fit between the two breasts (not the entire chest), by doing a two-piece mold, intended to fit the arc reactor kit.

Photos to come this weekend.

Standard Arc size is actually 3" , TC is redoing his with some information and meassurements I provided him.

Thank you very much for the catch; I had PM'ed earlier this week to check. My friend is planning on using one of his kits, so it will need to match.

I guess I'll watch that thread closer...

always wondered how'd it was done..post pix of your progress please!!

Actually, I think that animated Gif is a behind the scenes look at the preparations for the scene where Pepper Potts helps Tony put the new arc reactor in his chest. They are making a cast of his chest so they can make a fake torso so that a 6 inch deep casing can be inserted into the chest. Robert Downey Jr didn't wear any extra latex on his chest while he was walking around with the arc prop. The actual prop he wore is only 1/2 in to 3/4 inch deep. I have been gathering a lot of info on this as I will be making some wearable arc reactors designed after the movie props.

The only time he may have worn a little latex on his chest is in the cave where it was supposed to look like they just did surgery. So latex was added to give his chest the raw wound look not to add depth.

Check out these links:

Iron Man, Chest Arc Reactor : Indy Mogul Epix HD FX Reboot - YouTube

Iron Man: Behind the Scenes - Robert Downey Jr (1/4) - YouTube

Also, I have heard from several sources that the arc reactor is closer to 3.5 inches. This includes the casing and/or the bezel/lens. I have also done my own analysis using many reference images and have come to the same conclusion. The arc reactor core is right at about 3 inches though if that is what you are talking about.

Thanks for the information, and especially the links, they are very helpful

I am still going to move forward with this project as planned, though. I want to create the false chest to have the poisoning look in Iron Man 2:



Having a false silicone chest would make this a reusable and easy costume rather than one that needs lots of prep.

Yes just the Arc itself is indeed 3" as I stated.

Propworx - 1007/Lot 33 - Iron Man Hero Mark I RT Unit

Further clarification: the diameter of the arc reactor itself (NOT including the silver rim) is 3"; I've been working with the diameter of the whole piece, including the silver rim, which is more like 3 7/16" or 3.5".

Good, it sounds like we are all on the same page on the Arc Reactor dimensions.

Although it would seem to me that making a fake chest, then preparing your chest and adhering the fake chest would be a lot more work than just gluing an arc to your real chest and adding some makeup for the poisoned look.

You can do it how you want of course and it is an interesting project. I think it would be cool to pull a full size/depth arc out of your chest.

Have a look at my Halloween project though. I just made a quick and dirty arc and glued it to my chest. Link in my signature: Iron Man gauntlet/arc reactor

"Easier" is totally a subjective thing

Some progress tonight.

Started with a mannequin.


I knew the dimensions were a bit small, so I built it up with clay and built a wall around where the piece would be. I don't have a livecast to run off of or I would have just started there.


Made and poured in alginate (didn't grab a picture of that setting, but it's all gooey and purple). When that dried, I carefully removed it from the mannequin. Here it is with most of the clay still intact; I would later remove this.


And now a couple layers of Ultracal 30 to get the bottom of the chest. I'm going to build the prothesis ontop of this chest and use it as a two-part mold so the edges are feather thin.


Plaster will dry overnight and I'll start the actual sculpt tomorrow.

Mold done. Some cleanup to do yet but it's looking very clean. I have the dragonskin ready to pour in; perhaps this weekend when my test subject is in town.

this is looking awesome! I can't wait to test fit one!