Iron Man mark VII foam build

Bogleo

Bogleo

Well-Known Member
Hello,

I am new to this forum and this is my first costume. Here is what I have so far. I made the cod, and most of the right shin.

DSCF2800.JPGDSCF2809.JPGDSCF2810.JPGDSCF2811.JPGDSCF2813.JPG

There is a problem with this part not lining up.

DSCF2815.JPGDSCF2816.JPG

I think I will cut a slice out like this so it will line up better.

slice.JPG

If you have any comments, questions, or suggestions, feel free to post.
 
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Update!

Right thigh is mostly finished, and I added the knee parts on the shins.

DSCF2843.JPGDSCF2845.JPGDSCF2847.JPGDSCF2851.JPG
DSCF2853.JPG

I printed and cut out the templates for the boot, after I tried scaling it to fit my foot. I taped the pieces together to see how big it would be.

DSCF2855.JPGDSCF2857.JPGDSCF2859.JPG


I think it's too small. I will make a bigger one soon.

DSCF2861.JPGDSCF2871.JPG
 
I have the raw foam thighs, shins, abs, chest, back, shoulders, biceps, upper and lower forearms, hand plates, helmet, neck and one boot done. I will try to post pictures of them soon.

I'm thinking of trying to do the hands, and possibly helmet in card stock pep. I have some questions.

First: I have some card stock already, but I don't know if it's the right kind. I'm thinking of figuring it out by thick ness. 20 sheets of mine are 5 mm thick. I live in the US, and I've heard 110 pound card stock is the stuff to use. Could anyone compare that to theirs?

If I make the hands I will use Zabana's hand file from Darkside501st's Mark VII thread. I read that Zabana's hands are hard to put together, and I don't have any experience with paper Pepakura. Should I try a generic easy file first? (not necessarily hands). If so, which one?

Thanks for the help

Bogleo
 
Really nice helmet for your first attempt. Had 2 tries so far and still not 100% satisfied with mine. All looking really nice so far in general as well.
 
Updates!

I have finished all the shin flaps, thigh cover things, velcro, and most of the straps and buckles. I applied some caulk as mentioned in JFcustom's thread to fill gaps and smooth seams. I plan to seal soon with PVA glue (Elmer's glue all), and plastidip.

4some.JPG

I also made one glove using the files in JFcustom's mark 4/6 and 3 rar file. For the fingers, I used Zabana's original paper files, and did my own unfold for foam. I used the longer fingers file, since they fit better. Unfortunately I couldn't save my unfold because I don't have the paid version of Pepakura Designer. Maybe someday.

4some 2.JPG

Hope you like it and thanks for looking. :)
 
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Hello RPFers,

My suit is partially painted now. Here is the process I used. First, I lightly ran a heat gun over the foam. Next, I sealed it with 3 layers of undiluted Elmer's glue all (PVA glue), and 3 layers of Plastidip. I painted all of it red, and next I will do the gold and silver. Some things I learned are that sealing it with Elmer's glue makes it a lot more rigid, and smoother. Before I sprayed on the Plastidip and paint, it cracked very easily. The Plastidip makes it more durable, but it could probably crack if you bent it.

For the neck and hand plates, I didn't use PVA to seal them before Plastidip. I just used a heat gun and Plastidip. It works, and here are the differences.

1. The surface isn't as smooth. You can see the surface of the foam underneath.
2. It is a lot more flexible, and less rigid/hard. You can bend it more, but there is some small cracking. It's mostly unnoticeable, though.
Another thing is that if you use non-metallic paint, like I did, it won't really look like metal. (Obviously) :) I'm okay with that, especially because it is my first costume, but if I ever make another one, I will look into metallic paint.

Thanks to laellee for all the info for the sealing and painting process. :)

Anyway, here are the pictures.

DSCF2920.JPGDSCF2922.JPGDSCF2923.JPG

Next up to do is:

1. Paint the gold and silver.
2. Make the other hand and boot, and seal and paint both sets, and the foam helmet.
3. Install lights in the hands and chest.
4. Make a helmet from traditional Pepakura. I already have most of the card stock one made, and I have some fiberglass resin and bondo.
 
Last edited by a moderator:
Looks awesome!

When you start shooting your metallics, pick a small area to mask first and test-spray that. I've started to have some paint-reaction between the base colors and the metallics again, even after letting them cure a week or more... It's only in a few small areas, but still enough to need refinishing.

Anyways, once I saw it happening again, I decided to be proactive. I've been masking each area, then first shooting a coat of Rustoleum automotive primer . Then I let that set up for about an hour before coming back with the Metallic. I just applied the Metallic like I normally would, spray 1 coat, 20 minutes, repeat 2-3 times.

I'm not sure why the paints are still reacting sometimes, but the primer layer seams to be fixing it. The Rustoleum just say 'automotive primer' on it, I think it comes in several colors (I used red).
 
Mine actually was the Stops Rust Automobile Primer.... I don't see why you can't use that stuff, either. I'm still getting some small areas reacting, so I'm just letting the finish dry and then I'll lightly sand and shoot again. The stuff you have will likely work even better, if it's meant to be a filler as well then it will be heavier and flow nice.
 
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