Iron Man Mark 3 - Beginner

ShadowAssassin · Aug 25, 2013

Hey everyone, this will be my first post so please forgive me if I make a mistake.

Back just after Easter I had the desire to make an Iron Man suit, but original ideas were just terrible.
I started to learn about Pepekura and then found out a lot about the craft. I originally started using the paper templates and created paper models but I got really frustrated with how time consuming and annoying the Fiberglass resin is so that's when I moved over to Foam.
I obtained Dancinfool's Foam Pep templates and was going to purchase foam from "Wandyfoam" on eBay but now they don't supply foam which I was at the belief they would restock there store... but after waiting two months I knew they weren't going to.
Weeks later I was shopping around the Reject shop when I found 9mm Yoga squares for $12 (4 in a pack) and purchased one set which later lead to much more.
I then began my Iron Man project with A LOT of trial and error (As you can see in the first image)
I improved my technique with using the foam as when I began I was rather sloppy.
I have been using the 9mm foam on the pieces I wouldn't mind larger foam but I can't start other thinner sections (e.g. Neck, arms, abs) until I find a thinner foam but not at a ridiculous price!
So far I have briefly done both legs, thighs, pelvis and chest. When placing the templates onto the foam I usually join the templates all into bigger pieces (I am messy with glue) and then plan to later go over it and groove the extra detail.

Updated Mark6 suit-

Updated -

ry early work (S#!t)

Next stage

New Chest next to old.

New chest (Detail and extra work still needed)

Leg in progress

Leg on (Hinge not added)

Leg off (Hinge not added)

Chest, Hips, Thighs and legs (What's done so far)

Notes: Need to fix knee on one leg. Need to add little little drop in one Thigh. Need to finish Hinge joints and few parts on legs. Need to add grooves and detail to all (When all pieces are done)

Shiftyste · Aug 26, 2013

hey, looks good so far, im a beginner too but my build isn't foam... how long did each piece take you out of curiosity ?
Im working on a mk3 suit aswel I might make a thread when ive got the back piece done

Ste

ShadowAssassin · Aug 26, 2013

Well I haven't been working on the suit as much as I'd like but usually 2 days a week and I manage anywhere between 1-2 pieces.. The first Shin and Thigh took me a day each but lets say 6hrs+ for thigh and 8hrs+for Shin. Then when it came around to the second thigh and shin I had a bit more of an idea what I was doing so about 5hrs+ each lets say..
I plan to use a hot knife to add the detail, I got the idea from Impact-Props.

ShadowAssassin · Aug 29, 2013

Finished the abs yesterday but am debating whether to join it all as one piece or have it divided into two pieces.. I am using 9mm foam so I think it won't look neat enough to be in two parts.. (The prop used in the movie was latex and each section fell into the next giving the actor/stuntman better movement)

I have also just about finished the left arm..Just a bit more gluing 'Sigh'

Beer_Money_Props · Aug 29, 2013

Looking good for your first build.

As to the "first timer playing with foam" feels...I had those as well. The stuff is pretty forgiving, but my ability to accept anything less than great...yeah, not so much...

Keep up the good work!

ShadowAssassin · Aug 30, 2013

Thanks! You can see from my first pic that I was absolutely terrible.. I still get the squirt of glue out of the parts but I plan to clean that up as best I can and fill in all the gaps before I add any additions and start painting parts.
I really like this as a hobby and plan to do more! I've planned for an Arkham Origins Batman for my next project but right now I can't get ahead of myself and need to focus on this for now.

ShadowAssassin · Oct 2, 2013

Just attached the back and chest together... I have to still add 1 of the dongles on the back and reshape on that's already added. After fitting on majority of the suit (All loose, not attached at all) I'm fairly happy, although the abs don't fit into the back correctly (I think it's because my whole suit is 9mm, and doing the 'step' technique where one piece sits above another makes one section in theory 18mm thick) So to fix this I may have to either take a tiny bit out of the abs as well as adding a little bit extra in between where the back and front join..
I have also made a harness made from straps and buckles which will join the limbs to the torso to keep it all in place.

ShadowAssassin · Oct 23, 2013

Another quick update - Got hold of some 2mm Foam ($3 for an A3 Sheet) 2mm was all I could get, I would have preferred 3mm.
Finished the neck (Other than the 'Dongles') Velcro has been added and gets the job done.
Right Hand (No LED Light) has been done, I still need to slightly adjust a few fingers but mainly just because of my big thumb and small pinki 'Ironic huh'
View attachment 245772

ShadowAssassin · Dec 4, 2013

Update: I had been absent for a while and had only been doing work a few hours around 2 days a week, this has been for several reasons, one because of other priorities, another being the release of multiple games such as GTA and Arkham Origns

Now that it's heading towards the end of the year I started stepping up my game a little working on in much more frequently. I am nearing completion and plan to paint not this week, but the following...But I was wondering if I need to add a coat of anything before I had my Primer followed by Red paint? I've heard others have used coats of PVA glue as well as certain resins... If I were spray the Primer onto the foam without anything else will it cause any damage or ripping to occur?

I was unhappy with the outcome on a few parts so just like several other parts I have redone them -
Abs: The abdominal templates were fitted to only fit 'against' the chest/back and not actually have excess that sat inside, I completely redid the abs and have reshaped it slightly as well as adding on extra levels.

Chest: I have redone the chest a total of two times now, my very first one 'which was a test and to get use to using foam' which I then replaced with a much more accurate chest but still with several flaws, I have just finished making the new one which I am much happier with!

I have been working on the LED part of the Gloves and have found a perfect sized LED that only cost $1 on eBay, I am then putting over the top a clear (But foggy) Water bottle lid over the top to give it that glow effect and so you can't see each individual tiny LED. I am using a 9V D battery which will be attached into the forearm.

I am getting some hinges for the legs and arms this weekend I believe, once I attach everything rather than having it bounce about I will try and upload a photo.

torx · Dec 4, 2013

the good thing about foam is that you can trim it down if the parts are too big.

as long as you know exactly where to cut, you can make huge oversized parts fit you better by trimming off certain edges and rejoining.

it takes several projects with foam and pepakura to really get a feel of proper measurements, better cutting and gluing skills. its all part of the fun though.

ShadowAssassin · Dec 4, 2013

torx said:
the good thing about foam is that you can trim it down if the parts are too big.

as long as you know exactly where to cut, you can make huge oversized parts fit you better by trimming off certain edges and rejoining.

it takes several projects with foam and pepakura to really get a feel of proper measurements, better cutting and gluing skills. its all part of the fun though.

I know what you mean, at this point I am only just starting to get good at working with foam, in my first pic you can see how terrible my first chest looked, a lot of this has been testing new methods and strategies but I think I am getting comfortable working with the foam

torx · Dec 5, 2013

my peeve is having to resize, reprint, recut, then recut foam if something is too big or too small.
sometimes i try to figure out how to resize without doing everything over again because its a mental challenge.

which is why i respect the Philippian prop makers here that can build a complete suit in one week. boggles my mind.

ShadowAssassin · Dec 12, 2013

I've now finished both Biceps, I had to scrap my original one as it looked dreadful! So at the moment with progress, all parts have been made (Other than boots) But this does not mean I haven't finished fixing a few things here and there, I'm getting some Chicago Screws this weekend which will pivot the legs and arms. At the moment I haven't added the buckles and straps to join everything together...But I assume that won't take too long... I haven't added in the Shoulders yet as I need my Chicago Screws first so they can hinge and then actually be added onto the biceps.
Still need to add a section on the thighs with 6mm Foam.

Bigturc · Dec 17, 2013

Hi shadow,

First of all, I think you're very good at this foam thing, so congrats on the parts, they look really clean.

Now, I'm taking you have this build thread up for critic and comments .. and although your pep is clean, I think your parts are way too big on you. Biceps, thighs and the torso looks way out of proportions. That's my 2 cents .. do whatever you want with it!

I'd suggest working them out, 1 part by part, adjusting scale as you go .. and don't move up to the next before you figured it out! Same goes with the arms, do a full arm, then when you're happy on the scale, copy that on the other side.

Whatever you decide, keep up the hard work!!!

ShadowAssassin · Dec 19, 2013

Bigturc said:
Hi shadow,

First of all, I think you're very good at this foam thing, so congrats on the parts, they look really clean.

Now, I'm taking you have this build thread up for critic and comments .. and although your pep is clean, I think your parts are way too big on you. Biceps, thighs and the torso looks way out of proportions. That's my 2 cents .. do whatever you want with it!

I'd suggest working them out, 1 part by part, adjusting scale as you go .. and don't move up to the next before you figured it out! Same goes with the arms, do a full arm, then when you're happy on the scale, copy that on the other side.

Whatever you decide, keep up the hard work!!!

Thanks for the comments

I was on the same boat as you with the sizing of the arms and other certain parts, my first thoughts when I recognized these were #1 I don't have too much meat on my bones haha, I'm rather tall but not wide

and #2 I'm using the 9mm foam so that would make the parts slightly larger..
I am copying the templates for the scale of their print, I did not alter the scale at all, Dancinfool mentioned that the templates were designed for anyone 6 foot give or take either way (I am 6 foot and only 15yrs old!). I was hoping as I'm still growing and expected to get taller that I could have some room to still grow into the suit. I do plan to do a Mark 6 in future so it may be a good idea to slightly scale down the files to work for the thicker foam and my body build, for me all this is a learning process and I wish to gain more skill, knowledge and confidence with cosplays.
I’m happy with the scale of the torso section (Chest, abs, Pelvis) Although I have altered the shape and size of the abs roughly 6 times, twice since the last image was uploaded, I still feel it should be slightly skinnier :/ I’ve been doing all my hinging for arms, legs and shoulders and I’m prepping for painting before Chrissy!

ShadowAssassin · Jan 1, 2014

I am preparing to paint now, I just need a bit more spare time haha, I will first do 1-2 coats of plastidip as my sealer, add a primer then move onto my red and gold possibly followed by a clear gloss finish

I have just a few quick tweeks to make..
I need to reshape the shoulders a bit tighter and curved.
I need to re-cut a section on the thighs and re-angle them from 45' to 90' because it's making me look like I have fat hips :')
That's basically it, I did the boots a few days ago using a box I had kept with scraps that were a decent size and for scrap pieces it turned out alright, the boot was made from the 9mm which I thought would make it look far to bulky! But turned out pretty fair, still bigger than using 6mm but It's better than wearing Nike's with the suit haha. The back heels I used a black 6mm foam so It helps reduce the appearance of 'bulky'

ShadowAssassin · Jan 21, 2014

I got around to spraying some Plasti-Dip and testing some colours. I have sprayed 1 can of Red Plasti-Dip on several pieces, I went back to get more cans and they had sold out! Just my luck! More is meant to come in this week 'sigh'
I decided I will test out the colours I bought on one of the elbow pieces, the primer works well although I feel the Red I chose is slightly too dark

It looks rather dark in person but when I took a photo with the flash it looked a whole lot red'er..? When I go down to pick up more Plasti-Dip I'll have a look at a better alternative of paints.

I also constructed a working arc reactor made from a torch, PVC pipe (Which size matches the cut out of the foam perfectly!), a paper cone used to fill in the size of the torch to match the PVC, clear plastic from the back of a DVD case and finally I cut the bottom of a bottle of soft drink to use to hold in all in. This was simple yet very effective - I may make a photo of the construction.

RichLather · Jan 25, 2014

If you're in need, here's a very reliable source for Plasti-Dip aerosol spray.

McMaster-Carr

ShadowAssassin · Feb 11, 2014

Lack of updates is due to starting a Mark 6 build.

Around two weeks ago after I FINALLY finished all the parts with the Mark 3 and all that was left was the PlastiDip (which I have now done 95% of the parts) the only thing left was painting.. I don't have a very open time schedule for this as I myself won't be doing either of the Red and Gold to begin with [I still have to practice a little more, that's why it was good I did the PlastiDip and doing the Primer for some pieces

]
I did a fair bit of research on others doing the Mark 6 build (Mainly Stealth and Drack) along with several others, all used similar methods with some variations from each separate builder. I already have thought out how I wanted to attack this build...somewhat..

Just from the 2&1/2 weeks I've been working on it I've build the Cod Piece, Abs, Back and Chest (Insanely fast compared to the Mark3 plus the parts are much cleaner) I've joined the Abs and Pelvis together into one piece other than the abs plate itself which is removable for easier accessibility.
Unlike my Mark 3 build I'm making the Chest and Back connect with Buckles and Velcro for if I get around to it I'd like to make a Mark 4 chest that can interchange with this suit.
Rather than me just keep on rambling on I may make a thread....Yes I'm aware that there is a whole lot of them already out there but I still think I might..

ShadowAssassin · Mar 31, 2014

I figured as I haven't posted in a while I should just show a little update on what I've been up to recently..
I've still been doing the Mark 6 work, I've finished 90% of the foam build as of last week (I've had a week off from doing Iron Man work) and the only things that need to be made is the neck section from the Brace PEP file which I will be attaching onto the back. Two pieces are being scrapped and redone, the left forearm is being made slimmer to match the right, and the Abs plate I will be making a new one of with extended sections so it will stay in place. I still have the helmet which I am still yet to even work on since the Mark 3 suit started.
I am also making the Mark 4 chest piece which I have managed to interchange between suits simply by using buckles, however when changing over chest pieces the colour scheme will have to stay as the Mark 6 Paint job!

Mark 6 Chest after I started adding 'some detail'

Full suit

Suit test fit (Fits perfectly!)

Any comments would be appreciated!

- If I plan to get better at this line of work I need to know the pros and cons of what I'm doing..

Iron Man Mark 3 - Beginner

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