Sandbagger's Iron-Man builds - Now in STEEL

sandbagger · Mar 4, 2016

Trial fit some 5mm foam padding with a bit of hack and slash while in the helmet. It's a little snug, especially on the extremes of the zygomatic bones - so now I have it all worked out in shapes I can trace it onto 2mm foam and fit that in with nicer cut edges.

stigmorgan · Mar 4, 2016

Mind officially blown.

sandbagger · Mar 5, 2016

Brainstorming in the shed tonight but my brain wasn't cooperating much. Still, after a sit down and a few uppercuts, I managed to get the grey matter to work for a living.

1. Experimenting and making a DIY linear actuator for the helmet face plate.

2. Building tiny mounting plates for micro switches.

3. Micro switch mounted on the upstroke hinge. I've made them adjustable so I can tune their height once the actuator is connected.

4. Micro switch mounted under the downward faceplate hinge. This bracket will be re-made as one piece. I had to make it in two for prototyping to get the angles right.

5. The plotting continues. Linear actuation concept drawing. How to attach the actuator to the hinge.

sandbagger · Mar 6, 2016

Prototyping some under-armour tech.

And a photo just because.

305primus · Mar 7, 2016

When I saw the title I thought for sure you were kidding about the steel part but no you really are that much of a badass you are making a iron man suit of steel I agree with stigmorgan on this one mind officially blown keep it up mate

Skickat från min Nexus 7 via Tapatalk

sandbagger · Mar 7, 2016

305primus said:
When I saw the title I thought for sure you were kidding about the steel part but no you really are that much of a badass you are making a iron man suit of steel I agree with @stigmorgan on this one mind officially blown keep it up mate

Skickat från min Nexus 7 via Tapatalk

Thanks mate.

Update:

For the under armour tech around the arm and shoulder - a few bits and bobs from around the shed plus a small internal compression spring from Bunnings and a shocky magically appears.

Now to make fifteen more.

Also bought a fish-weighing scale for fifteen bucks to measure the force on the faceplate hinges. Will help me calculate the strength of motor needed to drive my linear actuator.

305primus · Mar 8, 2016

sandbagger said:
Thanks mate.

Update:

For the under armour tech around the arm and shoulder - a few bits and bobs from around the shed plus a small internal compression spring from Bunnings and a shocky magically appears.

Now to make fifteen more.

http://i.imgur.com/4xbQisP.jpg

http://i.imgur.com/FPI5XsD.jpg

http://i.imgur.com/tBqI3Gb.jpg

Also bought a fish-weighing scale for fifteen bucks to measure the force on the faceplate hinges. Will help me calculate the strength of motor needed to drive my linear actuator.

http://i.imgur.com/2x8yqHh.jpg

I wish you luck mate hope it works out for you it'll be awesome to see

Gus

Yodamann · Mar 8, 2016

Are those shocks functional?

sandbagger · Mar 8, 2016

Yodamann said:
Are those shocks functional?

Yes they are.

robo3687 · Mar 8, 2016

can I just say how cool it is to see something like this being made from my files all these years later?

awesome stuff dude...

sandbagger · Mar 8, 2016

robo3687 said:
can I just say how cool it is to see something like this being made from my files all these years later?

awesome stuff dude...

Can I just say how awesome it is to have Robo3687 comment on my build!!! Mate, I am not sure if you are aware of just how much your work has the capacity to change lives. From the first time I put paper to printer and ran off your files, life has taken me in some strange and wonderful places as a result!

I hope you can share in the satisfaction with me the day I walk into the first children's hospital ward wearing this and watch the kids EXPLODE with excitement.

God bless you and all your fellow pep developers mate. Thank you from the bottom of my heart.

SB

robo3687 · Mar 8, 2016

I'll admit I haven't been present over here for a long time (will be coming back more regularly now since I'm neck deep in a Kylo Ren build), so it's kind of overwhelming to see how much continued use there is of my stuff. It's really kind of cool that it's lasted this long.

Leylander · Mar 9, 2016

robo3687 said:
I'll admit I haven't been present over here for a long time (will be coming back more regularly now since I'm neck deep in a Kylo Ren build), so it's kind of overwhelming to see how much continued use there is of my stuff. It's really kind of cool that it's lasted this long.

Your files are still amongst the most popular I believe. I'm using them now for my build and it's pretty straight forward to work with for a beginner.

It has to be said that alot of imagination is being put in this steel build. Just to make sure it's wearable and functional. Hats off

brand · Mar 9, 2016

Hey SB! Awesome work as always! Make that thing fly too, please

Anyway, if you're looking for some under-armor inspirations, check this out. If you already didn't...

https://www.youtube.com/watch?v=aoa726WN1Rg

sandbagger · Mar 10, 2016

Thanks dudes. Brand I have seen that before and I will be referencing back to it a lot to get this to work. Cheers!

SB

- - - Updated - - -

Worked out a rough linear actuator for the faceplate hinges with more junk laying around in the workshop. It works good enough for the bush as they say.

Now to make a prettier, more slim-line one. I can find threads three times as aggressive and thus move the hinge a lot faster but you get the idea.

I've measured the pull on the hinges now and it's around 2.1kg. All I have to do is find a motor small enough, strong enough and fast enough to turn the chosen thread. There's a bit of physics involved trying to work out torque required and the speed needed to pull and push the nut the required travel, but I'm sure a boffin will step forward and assist where my brain chooses to exit the aircraft.

sandbagger · Mar 12, 2016

G'day gang.

I'm sorry I haven't been able to do much on the suit the last few days. I'm just bloody exhausted.

My work shifts and baby duties at home are not very Iron man friendly most of the time. I'll try to get some more done during my break at the end of next week. (If you could call it a break...)

I threw it back together today with all the work so far and took a few motivational shots for your entertainment and my focus.

joberg · Mar 13, 2016

This is all looking mighty cool mate! Thanks for the vids and keep up this insane work!

sandbagger · Mar 14, 2016

I get to tinker a little bit now and then. It's getting really fiddly now. Now I know everything works and fits, it is time to make it all pretty.

sandbagger · Mar 17, 2016

I took some time this morning to design a better actuator for the faceplate, based on suggestions from my anonymous engineering benefactor. I have the motors now and he has the gears, We have some bench testing to do then fabricate it. This morning he and I fabricated new hinges of aircraft-grade aluminium.

We've done the maths on the torque required under this new system, which equals a much less powerful motor. No gearbox required now.

All we have to do is regulate speed with either a resistor or PCB control. We'll work that out in the bench-testing phase.

sandbagger · Mar 18, 2016

GENIUS!! Thanks to Dan, AKA, "Dakiller" on the Overclockers Australia forum who drew a line on a photo of my circuit board and told me to cut it. Problem solved!!! Arc reactor now powers up and STAYS ON. Touch feature disabled. Done and dusted!

You sir, are a GENIUS! Finding it was so hard, but doing it was so simple!

I know a lot of kids are not going to be disappointed by Iron man's reactor switching off half way through a hospital visit.

So happy!

Baz.

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