Hi all, just wanted to say thanks to Darkside for the Iron Man Mk 7 templates, everyone who did the foam versions, and all the useful info shared on this forum. This was of massive help with the costume we made for our little boy this year, and it was a hit at the Halloween parties! I only discovered you could build a foam replica suit in such detail two weeks before my son's first party so we couldn't do all the pieces for a full suit as awesome as everyone has made on this thread, but we managed to put together something nice that he and his friends enjoyed.
Here's a video of the build and the final product, hope you all enjoy:
https://www.youtube.com/watch?feature=player_embedded&v=-Fje5M3kfmg
Oh, and I think I missed out thanking Stealth, I relied on his tutorials to figure out the tricky parts to the foam build. Huge thanks!