This is incredble, thanks for sharing all of these awesome files and pictures! I had no idea that a costume like this would even be in my possible reach, but now I'm really excited to give it a try.
I have a big question though (I looked through the threads and forums, but I might have missed something. And I'm really sleepy. -__-): Has anyone modded this for a girl? Or have any other gals built the Mark 4 with 'adjustments'? I found an awesome Pepper "Rescue" thread with pep files, but I would actually like to still have Tony's armor (or should I say "Toni"?), albeit with girly bits. But if worse comes to worse, I'll just be a very very very short Iron Man and find a voice changer, ha ha. (I'm 5'3" and a girl, if it wasn't clear. LOL)
Anyway I'm looking forward to it! Just bought some mats at Harbor Freight for only $9 but they're 1/2 inch... TT^TT I've seen some people do amazing things with 1/2 inch, and I really like the idea of it being sturdier, but for the arms and legs I'm definitely going to have to find the 1/4... I couldn't resist the deal at Harbor Freight though...
Thanks again for the inspiration and the resources!