Fiberglass tips

[milk_man]

Ive started designs on an iron man suit for mardigras but I dont have a large budget to make it. Sintra costs an arm and a leg out here where I am (86$ for a 4by8 sheet) and I had noticed some people making great masks out of simple fiberglass.

My original idea was to make the suit out of posterboard, the kind you get at the drug store kids do presentations on but I have a feeling it would be very fragile, hard to paint well and overall awkward. Thicker cardboard would be near impossible to curve (just turns out with creases). So now im wondering how hard it would be, with no experience, to fiberglass it and build the original parts from posterboard.

As far as I know fiberglass is just mixing resin and painting it on with layers of of material and letting it harden. I guess im asking if anyone has had success with just simple paintbrush fiberglass and sanding in making something like this, and if its very expensive or hard to come by?

Any help suggestions etc appreciated, and ill make sure to post up lots of pics if I pull this off

 

[Tim Allen]

http://www.youtube.com/watch?v=30sN5NLa7Ic

 

[Yodajammies]

Holler at Belacore out at the 405th.com

There are a couple really nice pep suits over there for download.

 

[weaselflinger]

"Fiberglass" actually refers to the glass fibers that are lamimated with polyester resin. Fiberglass is available as a wozen cloth or as chopped matt. Bondo makes a good polyester resin and if you can find it at a hardware store, it's usually about $25 USD for a gallon. If you can't find it a hardware store, try a auto supply store (where it will be more expensive). You can also order it online, but it's considered a hazardous material so shipping is expensive.

Working with polyester resin and fiberglass is tricky depending on what you are trying to do and how much experience you have. People are doing some very nice work making HALO armor with a method you desribed. You may want to search for those threads.

The movie ironman armor is very complicated (even more so that HALO armor) especially since nearly all the armor pieces overlap or fit together in a way that would tear itself apart if not very strong and well engineered.

 

[clonesix]

Be clear from the start what your budget will be first.

I can tell you that making an Iron Man suit out of any material is going to be expensive. Once you add up all the materials, paint, and effort, it is a big project.

Fiberglass is simple, but not easy. And don't forget "Messy"

 

[milk_man]

That tutorial I found linked to your spartan helmet gave me alot of insight Tim. I wonder if i would even have to fiberglass it, or if I could just resin the pieces for that extra support im looking for.

My budget isnt really limited, but im hoping to get one of Weasels beautiful helmets, so after that 250ish im not looking to spend an overly large ammount extra (50-100bucks) which I know may sound ridiculous but I believe is doable.

My biggest inspiration has been a guy over on the dented helmet. His whole suit is made of halloween costumes/posterboard and sharpie with paint. Im not looking to make a movie replica or anything, just something that people can look at and say holy crap its Iron Man Ive shot him an email for help and am waiting for a reply.

http://www.thedentedhelmet.com/showthread.php?t=21911

edit: He kind of hyjacked the thread, his suits half way down and on the 2nd page.

 

[JDarko]

just as an add on, resin is pretty brittle without the glass fibres, or at least something it can fill up with. I've seen fleece fabric being used as the fibre part on car subwoofers. The resin soaks in leaving a pretty sturdy, solid shape. But its better to use something fabric based/ glass fibres to add support than just hoping it will soak up enough into the card/posterboard.

 

[exoray]

Sintra costs an arm and a leg out here where I am (86$ for a 4by8 sheet) and I had noticed some people making great masks out of simple fiberglass.

First fiberglass isn't exactly "simple" it takes practice and it's a MESS! Second you won't save any money in the end, fiberglassing fabric isn't all that cheap and when you consider you need 3, 4, 5... layers the cost really starts to rise...

 

[milk_man]

Im not so sure. After watching a good few Halo tutorials people seem to be having great success with just resin and sometimes just a layer or two of material.

I didnt mean to simplify fiberglass, just didnt want people to mistake my available materials for the higher methods and machines.

I just downloaded pep and am amazed at how much easier it makes things. Id love to know if anyone has any high rez really good models for the suit.

http://theleagueofheroes.yuku.com/topic/4320/t/Iron-Man-costume.html?page=1

This guy is doing a great job but id love to see what else is out there.

Thanks for all the help so far guys, much appreciated.

 

[indiefilmgeek]

II just downloaded pep and am amazed at how much easier it makes things. Id love to know if anyone has any high rez really good models for the suit.

This guy is doing a great job but id love to see what else is out there.

Thanks for all the help so far guys, much appreciated.

Regarding Ironman pep files, I'm not sure which version you're hunting for, but I'd strongly recommend checking our Dancing Fool's thread on his VERY detailed pep files, HERE.

 

[indiefilmgeek]

Im not so sure. After watching a good few Halo tutorials people seem to be having great success with just resin and sometimes just a layer or two of material.

Regarding hardening pieces... Fiberglass resin and bondo aren't very expensive, but you are talking about needing quite a bit for your full suit. I'd guess you'll kill your $100 budget on just the materials for fiberglass resin, bondo, disposable brushes plastic gloves, breathing masks, etc. And that's if you're using old T-shirt or sweater material rather than the 'fiberglass' sheets (which are expensive to use).

Remember you have at least $50-$100 just in PAINT and other finishing materials. And that's doesn't take into consideration any lighting or other electronics you want to use or your under-armor detailing.

I'm certainly NOT trying to deter you from working in this material. It might be a bit more expensive, but I've really enjoyed trying it out on my build. I just don't think $100 will cover your cost.

***

On the other hand, several of us have had some very good luck working with the less-toxic and more comfortable EVA foam material. If you want to give that method a try, I'd recommend ordering the type of foam Graphic Jordan uses (it's also what I use), as it's MUCH easier to work with than camping or automotive mats. If you're not married to fiberglass/bondo, you should definitely check out Jordan's build -- I think you'll be amazed at what he's creating with 4mm foam!

If that's something you're interested in, check out STEALTH's tutorials on how to use pepakura files to make your armor out of foam... GREAT STUFF!!!

Good luck and certainly feel free to drop me an email or PM with any questions regarding your build. I'll be happy to help answer any questions I can. :thumbsup

 

[aron42486]

If you are trying to save money any woven fabric type material could be used in place of fiberglass cloth or mat. Old shirts, bed sheets, even paper towels. These alternatives probably will not be as light weight however.

One of your biggest road blocks is going to be time. If you are doing this for Mardi Gras then you have about 6 months to complete it. That is doable for someone who has worked with the materials before and has experience. Newbies should plan on it taking a lot longer cause there will be mistakes.

If you are not going for movie accurate and just want something recognizable then maybe cardboard creases arent such a bad thing. Cardboard is cheap, lightweight, and reasonably strong. The foam costumes can also be built very quickly and look great. Doing the full on pepakura, resin, fiberglass, bondo, finish method will take way too long, unless you are going to work on this for several hours EVERY day.

Your second hurdle is cost. If you are keeping this cost below $100 you are gonna have to sacrifice some details. Use as much scrap material you can find. Even going the foam route, I think you are gonna have to spend more than $100.

My recommendation, make the recognizable pieces look the most accurate. Use foam/cardboard/pep to make say the chest, back, shoulders and hands look good. Focus less on things like the boots, legs, arms, abs, and cod piece. Make those pieces out of a super cheap material.

It can be done in 6 months and for under $100. But it probably wont look perfect and it might not have the strength to last

 

[clonesix]

this thread is 3 years old

 

[aron42486]

wow, didnt even realize that. just saw it bump to the front, haha, wonder how it turned out