[WIP] Iron Man Mk 6 Foam Build - Now on duct tape dummy

kyxz2

Active Member
Hello RPF. this would be my very first post!

I've decided to show my Mark 6 progress.

I just hope I can finish it before Halloween. I only get 6 hours a week to work on it!

Please feel free to comment on anything, any comment will surely help!
Ask me anything as well and I'll be glad to answer any questions.

Just don't ask for money. :p

By the way, I'm 5'3 and 150lbs.

Here are the scales that I used.

Chest 25.41% - got the scale by measuring my chest width, 42 cm (includes 2cm allowance)
Back 25.41% - used chest scale
Abs 25.27% - got it by my abs width, 33 cm (includes 2cm allowance)
Shoulders 23.42% - this one is trial and error
Biceps, Forearms - I used the same scale as the shoulders
Thigh - 21.57% - this one gave me a headache. First, I got a scale of 20.578% by using the height of my thighs (37cm including 2cm allowance, width automatically adjusted to 16.8cm), I tried wearing it using a paper test but man, it only goes through half of my thighs, so what I did was to use the width instead, 17.7cm (including 2 cm allowance) and got the scale.
Shin - used the same scale as the thighs
 
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Re: Iron Man Mk 6 Foam Build - WIP

Materials I used:
  • 6mm foam rubber sheet (the type that they use for flip flops e.g. Havaianas) (For my fellow Filipinos, I bought it at E. Estanislao General Merchandise in Marikina City)
  • GRECO 88 turboglue (From the same store)
  • cutter
  • cutting board
  • a pair of scissors
  • a red marker and a blue sign pen
  • card stock for pattern
  • masking tape for tape test

All less than $15! Just make sure you know how to canvas and you will surely get the lowest price!
 
Re: Iron Man Mk 6 Foam Build - WIP

The patter I used can be found here:

http://www.therpf.com/f24/robo3687-iron-man-mark-4-6-pepakura-128147/

Before I start posting pics of my progress, I would like to thank all forum members here. I make sure I read any thread even if it's not about Iron Man. I get tips from them as well.

I've watched Stealth's videos on Youtube, xRobots, and, well, there are a lot of people on youtube that teaches you foam building, even if it's not related to costume making, watch it, I promise you will still learn something!
 
Re: Iron Man Mk 6 Foam Build - WIP

So I started with the helmet.

AxytKA7CAAAA6H-.jpg:large


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As you can see, my gluing powers suck big time!
The super glue I used burns a lot of foam.
And it smells bad!

A friend of mine who's taking fine arts told me a technique.
Just put pea size instead of putting glue on the whole side.

Make sure you don't inhale the fumes. It will make you high! Trust me! My fiance got mad and thought I was taking drugs because I was laughing like joker and flying like Iron Man.
 
Re: Iron Man Mk 6 Foam Build - WIP

Can you guys see my cutter on the 2nd pic? I had a problem with that, the blade is only about 2-3mm and my foam is 6mm. At first I had problems with it but I did found a technique. You need to have steady hands. What I do is to cut it a quarter of the way first, like outlining or redrawing your pattern lines, and then going back and pushing it all the way.

Now you have to make sure you have muscle memory and steady hands, because if you don't you will see like a staircase cut on the side of your foam.
 
Re: Iron Man Mk 6 Foam Build - WIP [PIC Heavy]

More Pics
Sorry for the topless pics, it was too hot!

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The white line on the forehead was caused by too much super glue.
I still need a heat gun to shape the faceplate.
 
Re: Iron Man Mk 6 Foam Build - WIP

Well done, you've taken the plunge.
It can be daunting putting your first projects out there but there are a lot of other inexperienced people that can relate to your progress better than many of the polished WIP's that we read. A lot of the more seasoned people take for granted steps that newbies are still trying to grasp.
It is good to have a broad cross section.
thanks for posting and keep up the good work

Paul T
 
Re: Iron Man Mk 6 Foam Build - WIP

Thanks PBT! We should never forget the basic steps of prop/costume making.
 
Re: Iron Man Mk 6 Foam Build - WIP

So I lost my photo with the ears. As soon as I find it, I'll post it.
 
Re: Iron Man Mk 6 Foam Build - WIP

Here's another pic of the cranium with jaw.

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By the way, I used a scale of 0.915744 for the helm.
 
Re: Iron Man Mk 6 Foam Build - WIP

I stopped working with my help because I'm undecided if I will glue the faceplate then cut it after sealing/bondo or shape it, seal/bondo it separately.

I was also undecided If I was going to put hinges on the jaw.

My final decision? Glue everything together seal/bondo then cut it with I don't know what tool. I've read of dremel tools but it's too expensive. I'm thinking of having it cut by someone who has the tools.

So my fellow filipinos, if you can read this, may I borrow your cutting tools after I seal/bondo/sand my helm? :p
 
Re: Iron Man Mk 6 Foam Build - WIP

alright, so while I was thinking of what to do with the helm, I decided to do the chest piece next.

And so I started to print the pattern, cut the foam and glue everything together.

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I forgot what scale I used here, it's about 23.xx, it's in my desktop at home, I'll post it once I get it.
 
Re: Iron Man Mk 6 Foam Build - WIP

So the problem with my super glue was it uses a rubber tubing that also melts if the glue stays longer in it.

After gluing the first part of the ribs, I decided to take a break first and I accidentally fell asleep. When I woke up, I had to say goodbye to my glue tube. Sucks to be me!
 
Re: Iron Man Mk 6 Foam Build - WIP

After doing the chest piece, we had a strong monsoon that caused flood that almost removed the Philippines from the map. I had to stop working first to take care of damages.

After the flood, I had a week vacation in Singapore. :) I love it there, I love the food and everything!
 
Re: Iron Man Mk 6 Foam Build - WIP

So after I came back here in the Philippines last week, I've learned that the shop where I bought the glue tube got flooded. I wasn't able to buy glue tube yet. But I started the shoulder with the help of my mom. Unfortunately the scale was too small so we need to start over again. But then I decided to start with the biceps instead so I won't get bored in making the costume.

Tape Test

*LB means left bicep

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Re: Iron Man Mk 6 Foam Build - WIP

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I'm not sure if it's too big or not, but on the upper elbow part, it will fit almost snugly since i'm using 6mm foam.
 
Re: Iron Man Mk 6 Foam Build - WIP

As you guys can see, I love bathroom pics.

Here's another pic with the new shoulder.

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Re: Iron Man Mk 6 Foam Build - WIP

I've already cut the foam for the biceps. I'll buy glue tomorrow and once I have the biceps glued altogether, I'll post the pic on Friday.
 
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