How did you sort out the inperfection at the seams of the foam pieces?
Cant wait to see your progress. Ive been thinking of getting a cheap paint sprayet and trying to apply the pva glue that way watered down. For a smooth coat.
Were you thinking smoothcast 300 for the plasic coat or something closer to plastidip?
Ok, so not much of an update on this as such, but I've backtracked a little and started a brain dump onto YouTube. Of specific relevance to this project are two videos so far on foam building, sealing & painting, and how I modified the pepakura templates manually for use with foam. The next one will be about moulding and casting the rigid pieces, followed by finishing and strapping etc.
XRobots - Iron Man & War Machine pepakura costume suit foam build, sealing and painting process - YouTube
XRobots - How to modify pepakura templates for foam, includes my Iron Man costume suit - YouTube
I have a number of other How-To videos on various subjects in my channel, and more to follow.
Great work. I'm from Southampton too have we met? You may have bumped into my creatures at a Con or something :lol
Paul
Good write-up. Thanks.Full details of the process are here: XRobots.co.uk - Wrap-around Moulds