Iron Man collapsible abdominal region and rotating forearm. Vids added.

Dirtsen

Well-Known Member
RPF PREMIUM MEMBER
Alright Guys, it's about time I start my own thread!
I've been lurking around this Forum for a while now. I almost started a Master Chief suit from Halo a few years back but the whole Pepakura ordeal was not possible for me as was still a student back then. It was just too time consuming and expensive so i gave up on that.

Now since I am a huge comic and movie geek I pretty much soak up everything I can. So it is no wonder that I am an Iron Man enthusiast. And when the time for Halloween came (yes, it has gotten a bit popular in Germany too)... I decided to go as Tony Stark. My idea was to get the Arc Reactor done and wear it under a shirt.




As you can see it is far from movie accurate but it did the job! It is basically a LED-taplight put into a sinkdrain housing. I used tinfoil and a reflector to diffuse the light in the back. in the front i used a small piece of tube and speaker wire plus an old air refreshener (yes it was a miniature tire rim) to create something resembling the arc reactors pattern. Under the shirt it looked like this:



After that was done I got a little more enthusiastic and wanted to build at least one arm and the hand repulsor, inspired by Robert Downey Jr.'s outfit at ComicCon. Since time was pressing i decided to go with foam. I used 3mm EVA foam which is called "Moosgummi" here and can be bought at every little crafting shop around the corner. So i got the edited Zabana glove files from JFCustoms thread an went at it. I then went for the foam edited versions of DancingFools lower and upper forearm because I liked that one the best.








The next step was painting the whole thing... not too much of a task... so i thought. But I had no idea what I should use to make the foam paintable and I had no idea what the German equivalent for PVA was. Plastidip wasn't available here either (so i thought) and time was running out. So i stumbled over a german forum where they explained that one should always use a certain german brand. I went to the local hardware store... they recommended the same... That stuff (Pattex Kraftkleber) was horrible to work with and made for a very disappointing surface texture on the finished pieces.


Just ignore my roommate... or not.


So as always:

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If you do your research right and take your time you will find what you need and you will be better educated than the "professionals" in the local hardware store.

But since I had no time left it had to be good enough. At least the paint made it look a bit better Here a few shots with the LEDs for the repulsor installed





So, after the big Halloween party, where some people told me how cool the costume had been (as the host I had the whole Tony Stark act down too) I thought: I can do better! So my goal is to get the whole costume done in time for the big opening night of Iron Man 3. I will be using Foam because it is easy to work with, less expensive and less toxic than the whole resining stuff. I have some ideas that I haven't seen anywhere else yet and maybe that is because it isn't going to work. But I'm stubborn and sometimes I need to learn from my own mistakes even when other people have tried the same before and failed. But sometimes that is a good thing :rolleyes
As for the templates: I am going with a Mix of files from JFCustoms thread. Just whatever works together and suits my taste. I also highly recommend Drack's thread for people that are new to "Foampeping" or working with foam. It helped me soooooo much. Thanks to all the guys who share their knowledge and experience so that we can have fun and enjoy doing this. Stealth, Robo, Drack, JFCustoms, Dancingfool and so on.

Ideas are:
- Using bearings for some joints like connecting the upper and lower forearm so that when you twist your lower forarm, the piece will move with it without the elbow joint being being twisted and so on.
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- use small bearings instead of Chicago screws in some joint areas to prevent friction on the foam parts.
- creating an undersuit so that there is no cloth shining through the spaces of the costume pieces.
- using rare earth magnets to hold the pieces together for easy assembling.
-Maybe using the German color scheme (Black, red, gold) for the final paintjob.
... and finally... make that thing fly for real! J/K of course.

These are some ideas I had to contribute to the already very detailed database of building the Iron Man suit (out of foam... or paper). If you have some ideas on what might (not) work go ahead. I appreciate your input. And if you are German and need some help with the things needed to get into foam building. I am more than happy to share my knowledge.
 
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Re: Eisen Mann! German Iron Man!

Alright Guys, it's about time I start my own thread!..

OMG, another "Blechmann", irgendwie erinnert mich das immer an den Zauberer von OZ... :D

The next step was painting the whole thing... not too much of a task... so i thought. But I had no idea what I should use to make the foam paintable and I had no idea what the German equivalent for PVA was. Plastidip wasn't available here either (so i thought) and time was running out..

But you know now what PVA is? It's just simple white or woodglue, Ponal for example...

And you can buy Plastidip on eba* or amaz*n, still with a golden mastercard in mind, it is much expensive here...

Instead of "moosgummi" do you think "trittschalldämmung" für laminat would do the same?

BTW, nice build.


RPF-standard-phrase: Can't wait to see it finished! :) :thumbsup



.
 
Re: Eisen Mann! German Iron Man!

After doing my research I have everything I need for building the suit. I know that PVA is wood glue but I found something resembling school glue which can also be used as a "window color". It stays a little more flexible than wood glue. I tried out some stuff before deciding to go with that. Also, I found PlastiDip in Germany but that stuff is too expensive. The site Modulor: HOME has a huge selection of all that material. Plus they have extensive Product description which helps a lot.
As for the "Trittschalldämmung": I do not recommend using that stuff. It is closed cell foam BUT with very low density. You won't be able to get good results with that.
IF you are looking for good foam here in Germany i recommend the site Unser Onlineshop. I use the 5mm and the 10mm foam with the density L45 (which basically means 45kg per cubic meter). I have also tried out the L29 foam but the L45 foam is easier to work with when it comes to cutting. And it holds its shape much better. It is the same stuff that XRobot uses i think.
 
Re: Eisen Mann! German Iron Man!

Thank you, I will post some pictures of my recent work tonight after work!
 
Re: Eisen Mann! German Iron Man!

Do you know, how sucky it sounds when you germanize "Iron-Man"? :D Damn… my ears…
 
Re: Eisen Mann! German Iron Man!

Yeah, to German ears "Eisen Mann" does sound lame. But I couldn't think of a better headline to start this thread ;)
As for the colour-choice... I'm postponing that until I get to that stage. First i have to seal the foam with PVA then we'll see.
 
Re: Eisen Mann! German Iron Man!

Alright guys, since I've shown you my first steps in working with foam in my first post. Here is some if my recent work. I started with creating a separate workspace other than my desk. If there is something us Germans are good with... it's organizing the S*** out of stuff. (Mind that the picture was taken whilst arleady starting to work on the suit) So...


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Next was scaling. I'm not going into that since so many posts cover that already. In my first try with foam i just cut out the templates and transferred the outlines onto the foam. This way a lot of details just got lost. So this time i cut out the templates with an exacto-knife (Bastelmesser/Skalpel) and fixated them onto the foam using pins. this way I could trace the templates with the Scalpel real easy and got nice, clean cuts. I started with the chest piece.



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Ignore the abs. They were a total failure and are just used as a stand for the chest piece.

Then came the back


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And the troubling experience of assembling the two... which is a huge pain in the A** when you forget the collar plates.

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After tackling the arms and the collar... the helmet was in order...


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A first assembly of the upper body parts... held together by masking tape:



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Now that was 3 weeks ago. Since then I redid the helmet since the first one was so snug plus I made a mistake with the two forehead parts... so back to the start.

This was just a quick update. If I get the time tomorrow I will post better pictures of the new helmet and the way i connected the joints of the forearm and the bicep. Also I use strong rare earth magnets (neodym Magnete) to hold the chest and the back pieces together without using buckles for easy self assembly. Also I started working on the abs. I plan on making it possible that the belly plates slide on top of each other when you bend over (yeah, I know that sounds weird). I understand that has been done before but I might have an idea that could work too.

Alrighty then! Who else got themselves some iron man in Germany?
 
Re: Eisen Mann! German Iron Man!

The chest peice and the gloves looked amazing but the abs look kinda weird and sunk in. A lot
 
Re: Eisen Mann! German Iron Man!

That is because they are upside down in the pictures. But they still suck, that is why it said in the caption to ignore them because they were merely used as a stand for the chest piece for taking pictures ;)
 
Re: Eisen Mann! German Iron Man!

btw in Germany for PVA: ist es Bastelkleber den bekommst du bei Woolworth für 2 Euro, ich habe auch ewig gesucht, weil Holzleim nicht wirklich das gleiche ist.

Viel Glück beim Bau, ich versuche es auch gerade mit dem Iron Patriot!
Gruß
Aus Düsseldorf
 
Re: Eisen Mann! German Iron Man!

Hey FreakT
Do you have the pep files for the forearm of the Iron Patriot? Would be very nice :)

Greets from Wilhelmshaven ;)
 
Re: Eisen Mann! German Iron Man!

Hey FreakT
Do you have the pep files for the forearm of the Iron Patriot? Would be very nice :)

Greets from Wilhelmshaven ;)

just wait for Jackie to finish modelling them when more reference is out.
 
Re: Eisen Mann! German Iron Man!

Alright guys,
it has been a while and i wanted to post this much earlier, but the holidays got in between and you know how it is. But... I got some work finished. The Cod Piece is done and the abs... those were a real pain in the A** but... let's check the pics for that.

In between everything I managed to finish one glove. I made it from 3mm and 2 mm EVA foam and put a gardening glove in there. As for the file I'm using... I am sure that i got it from JFCustoms thread somewhere but I can't find it anymore. It is not the EasyHands file that Stealth has. I started with the "Easy" files but I couldn't for the hell of it figure out how to put it together. I also thought that many details got lost so I decided to use the other file again. And I can tell you: It is NOT easy to use. I am using a G4 LED SMD bulb that runs on 12V but I am going to use a 9V battery to run them. I checked it in advance and it is bright enough for my use.

20130103215048.jpg


Let's get to it... the ABS... I used JFCustoms foam edit from Robo's original Pepfile mainly because it looked the best and since it has 4 different segments it seemed the best thing to go with since I was planning to make it a "bendable version which means that it shouldn't limit my movement too much. I had some sketches on how to do it. I ended up doing it the following way:

this is how the whole thing ended up after initially putting all the things together. Here the segments and the bellyplates are held together by pins.

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And the last picture of the finished pieces assembled together just to get a good idea if it fits together like that...
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If you watch closely you can see the masking tape on the side of the breastplate where the back and the front meet... I had to put a piece of 10cm foam in between there because the upper segment of the abs would not fit into the chestpiece. That's what happens if you use files from different people and don't plan in advance.
The bigger problem was: the Abs did not fit at all. the upper segment did, but everything else... nope! After being mad at myself for like 30 Minutes for not measuring right and eating all that good food at Christmas... for the last 10 years... I decided to FIX IT! I'm not fat mind you, I'm well proportioned but not innocent when it comes to snacking :D
So in order to fix it on my own (without someone holding the failed abs to my body to get the right measures) I build a 1:1 duct tape dummy of my abs region like this: http://diyfashion.about.com/od/diyf...=146&start=0&ndsp=109&ved=1t:429,r:2,s:0,i:91
Then i marked the outlines of where the Chestpiece and the Codpiece sits and put the ABS onto the badboy using pins.
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As you can see there was some space to fill in the front section plus the sides did not line up anymore. So I had to put some foamspacers in the back as well and subtract them from whatever I had measured in the front... sounds complicated... it was.
In the following pictures I had already widened the chestpiece for the Abs to fit inside them. I had also pinned the bellyplates onto the widened Abs. Now, the the lower segment is showing the black backfoam which is supposed to be covered. Gotta fix that too then...
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After hours of work... I finally had it working. I put foam spacers in th front and back to get the details lined up right again and also put clips in the front for easy assembling. I used the same clips to attach the abs to the inside of the chestpiece. Works like a charm.
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Here with the bellyplates attached with pins.
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And now the inside shot to let you see how i managed to make this a "bendable" abs section. The 4 separate segments are held together by several flexible strings. All my other ideas where too complicated to put into this little room.
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As for the bellyplates, they are going to be a seperate piece. the upper segment will be attached to the chest piece with buckles for easy assembling. The same goes for the the lowest segment and the Cod-piece. Also, the belly plates will have to be moveable... so that I can bend and stretch. Because what good use is the flexible abs-section if the bellyplates in the front are rigid? So I came up with some ideas. I have two that might work. One i was already able to try out: I measured and cut up some hard plastic (Hartschaumplatten) to build a mechanical system that will be put onto the back of the plates:
Here is the first draft with cardboard mechanics (you are looking at the back of the assembled bellyplates).
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Then with the plastic:
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Another option:
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The rubber strings are supposed to make the segments snap back into place and making sure they don't overstretch. I think the whole thing is self explanatory.
Right now I don't have all the materials to make this happen but over the next week it should happen. So tell me what you think, maybe you have some ideas on how to make this work even better.
 
Re: Eisen Mann! German Iron Man!

That ab section looks so great but I can't figure out how it works, any chance of a video?
 
Re: Eisen Mann! German Iron Man!

Thank you! When I get the parts I need later this week, I will post a video!
 
I am back with an update! This time MOVING PICTURES! Okay, since the Iron Man topic is a little flooded I will try to keep this as informative as possible. My goal was (and still is) to enhance mobility. So far, movement all suited up wasn't so good. I came up with a few ideas and you are welcome to use them or improve them (and share with us of course). Here are some demonstration videos I made for you guys.

First, the belly plates. If you want to pose right as Iron Man it might be necessary to stretch or bend. With these belly plates, your ab-region performs just right without showing any skin.

Iron Man Foam Suit collapsible belly plates - YouTube


Second, the rest of the abdominal area. They don't need to be as flexible as the front, but still. I already showed you some pictures of this part but since I was already using the camera...

Iron Man Foam Suit abdominal region - YouTube


Third, I thought you might be interested in a rotating Forearm. I planned to use a bearing for this but they are too expensive, too heavy and just not practical for what I was planning. So I came up with something myself. My goal was to make it possible to twist the forearm 180° but 90° is enough (the normal human joint can't do 180°). Right now the assembly of my setup is a little off, so 90° doesn't work in the demo but it is possible. I will take pictures of the internals to help explain how it works later.

Iron Man Foam Suit Forearm rotating joint - YouTube

I hope you can all understand my English and these tips help. Now some feedback please

P.S.: How does the embedding works here? I tried every embedding option youtube gave me but it did not show up in the Preview like I planned. I'm sorry for the external links.
 
I'm liking the ab section. A little more involved then my thoughts but thanks for sharing. I
My build is a steel build and I am going to have a flexible ab system. I might use some of your ideas. Again thanks for sharing!!
 
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