Foam Iron Man - Mark III - Bigturc's bolts!

[MorbidCharlie]

Hello, RPF. Yes, it's another Iron Man build, but this is special to me because this is my first foray into cosplay and more specifically, trying my hand at a project of this type/complexity. But first, a little about me:

I've been a lurker here for a little while and seen some amazing projects, but none (to me) as cool as some of the Iron Man builds out there. I originally ended up here because I love Tron and wanted some ideas on how to pull off a Rinzler costume, but after seeing the material and research available for making Iron Man builds (and having seen all the Iron Man movies) I decided an Iron Man costume appealed to me more. So here I am.

I've decided to work with foam, given my inexperience and time constraints (hoping to be done by Halloween '12) and with lucky timing, Dancin_Fool has released his foam templates for the Mark III, the suit I like the best.

I'm going to try and document as much as I can as I start this build so that others can learn from my successes and failures. So here is where I am going with this project currently:

Build:

• Helmet: Sharkhead7854's helmet modified for foam by j0wE (located in STEALTH's foam thread)
• Hands and feet: Zabana's pep files
• Potential alternate hands: j0wE's easy hand files
• Remainder of suit: Dancin_Fool's Mark III pep files for foam
• Arc reactor/Unibeam: TBD
• Lights for eyes: TBD
• Repulsors: TBD
• Bolts: Bigturc's hip pods and bolts

Finishing/painting options:

• XRobot's plastic coating method - This is my preferred option
• docholiday78's rondo method
• indiefilmgeek's painting method

Materials:

• 110 lb cardstock - for cutting out the templates to be traced on to the foam.
• Hot glue gun and glue sticks - gluing the pieces together
• Hobby knife w/ replacement blades and cutting board - Cutting the parts out of paper and foam
• Scissors - Cutting the parts out of paper and foam
• 3MM "Funky Foam" from Hobby Lobby
• Two rolls of foam purchased from Academy Sports
• Heat gun - shaping the pieces better.
• Scissors - trimming the pieces after they have been cut from the foam.
• Mat cutter - allows for 45 degree cuts for easier attachment of pieces.
• Toothpick - for applying glue to peps
• Beacon's felt glue - magical glue that has enough tack to grab pep pieces quickly, but dries slowly enough to move them about for better placement.
• Angle cutting knife

Future upgrades/enhancements

• Fiberglassed pieces
• Motorized hinge system for helmet
• Other motorized pieces (flaps, weapons)

Special thanks

• Special thanks to Dancin_Fool, Zabana and Big Turc for patiently answering my noob questions.
• STEALTH for his awesome tutorials - The Hero Tutorials
• Dancin_Fool, STEALTH and j0wE for the foam templates
• Numerous others who have patiently answered my questions and encouraged me

 

[Moth]

Re: Another Iron Man - My journey begins... thanks to the RPF!

Welcome! I, too, am starting my adventure into costuming with the Ironman project, and you couldn't ask for a more helpful place to share and ask questions!

I'm doing a foam Mark IV myself, and eventually I'll make my own thread for my progress (I've only completed a cardboard mockup of the helmet so far), but if I figure out any nifty tricks I'll be sure to post 'em.

Regardless of what medium you choose, I wish you luck!

 

[SemperBourne]

Re: Another Iron Man - My journey begins... thanks to the RPF!

Question...you both joined the rpf a really long time ago.Why so little posts and how come you just started? LOL.not trying to sound rude or anything. Im just curious.

 

[hatman33]

Re: Another Iron Man - My journey begins... thanks to the RPF!

Goodluck to both of you. Enjoy your builds!!!

 

[Moth]

Re: Another Iron Man - My journey begins... thanks to the RPF!

Question...you both joined the rpf a really long time ago.Why so little posts and how come you just started? LOL.not trying to sound rude or anything. Im just curious.

I can't speak for Charlie, but as to my own post count...

I lurked around early 2009 until I finally decided to join. However, I was always so amazed by what everyone was producing that I didn't really feel I, personally, had much to contribute (or at least, nothing that hadn't already been said a million times). Since then I've had a lot of life issues arise, and my interest in props and costuming didn't spark again until just recently. I just happened upon the RPF one day and remembered just how awesome this place (and its people) are, which got me back on here.

Now that I'm finally creating something of my own, I think I can finally justify increasing this meager little post count

 

[MorbidCharlie]

Re: Another Iron Man - My journey begins... thanks to the RPF!

Question...you both joined the rpf a really long time ago.Why so little posts and how come you just started? LOL.not trying to sound rude or anything. Im just curious.

The short list: wrapping up a divorce that went on for too long, marriage, and my second child was born. Been a little busy.

I'm finally in a place where I can start work in earnest.

 

[jamesrickards]

Re: Another Iron Man - My journey begins... thanks to the RPF!

The short list: wrapping up a divorce that went on for too long, marriage, and my second child was born. Been a little busy.

I'm finally in a place where I can start work in earnest.

YAY more ironman stuf!!!

Ive started my suite (war machine ) and I'm loving it!

I do abit as and when I can -weird thing is everyone is KEEN to see it!

Good luck!

 

[MorbidCharlie]

Re: Another Iron Man - Mark VI Helmet Pep started - pics inside.

Started pepping Sharkhead's helmet that came with Robo3687's Mark 4/6 files today. Here's where I am:

Sorry for the blurry pictures for the side shots. I have a question for those that have pepped before. If you look at the last photo, the center piece hangs over a little. This is my first pep attempt. How crucial is it that the pep be perfect if I am going to fiberglass this? Is this something that I can correct when I fill and sand?

 

[MorbidCharlie]

Re: Another Iron Man - Mark IV Foam

I've been looking at XRobots foam build thread and saw the results that docholliday came up with using foam. I've looked at Robo3687's foam templates and they look much easier to work with. I think I am going to go that route and make myself a Mark IV suit.

 

[bustermedic]

Re: Another Iron Man - Decided on Mark IV foam build.

I got extremely frustrated with the standard pep/ rondo/ fiberglass route. I'm working on a foam IM MKVI build at the moment, waaaaaaaay easier to work with in my opinion. Only downside is that I don't have as much time to work on it as I want to!

 

[MorbidCharlie]

Re: Another Iron Man - Decided on Mark IV foam build.

Well, I started to pep one of Zabana's boots... and realized that I printed A4 to Letter. The boots might fit me... if I was 12 years old. :lol Back to the drawing board.

 

[rosskow]

Re: Another Iron Man - Foam/Fiberglass hybrid.

the accuracy of your pep build isn't crutial because as you said you'll be fibreglassing and bondo-ing it.

the pep build between the fibreglass and bondo of my build isn't recognisable.

 

[MorbidCharlie]

Re: Another Iron Man - Mark III is go!

Updated the intro post.

Haven't had a whole lot of free time, so I'm getting a slow start but tonight I was able to finish cutting the paper pieces out and begin tracing them to the foam. I'm hoping tomorrow that I will be able to assemble my first Iron Man helm!

 

[jackieisrockin]

Re: Another Iron Man - Mark III is go!

Hi! If you want, i could 3D model an arc reactor for 3D printing if you want it for your suit. Just a suggestion

 

[MorbidCharlie]

Re: Another Iron Man - Mark III is go!

LOL jackie... could you just 3D print the entire suit for me? That'd save me a lot of time. I don't know how much time it takes, and I can't guarantee I'd buy it, but if you're inclined, I'm certainly interested in seeing what you come up with.

 

[jackieisrockin]

Re: Another Iron Man - Mark III is go!

LOL jackie... could you just 3D print the entire suit for me? That'd save me a lot of time. I don't know how much time it takes, and I can't guarantee I'd buy it, but if you're inclined, I'm certainly interested in seeing what you come up with.

Well then what kind are you looking for? The actual arc reactor or the unibeam pieces that goes over the arc reactor when the armor goes on?

Arc reactor:

Unibeam: View attachment 98006

 

[MorbidCharlie]

Re: Another Iron Man - Mark III is go!

The unibeam... guess I should edit that in the first post so that there's no confusion.

 

[MorbidCharlie]

Re: Another Iron Man - Mark III - first helmet (in)complete!

So I put together my first helmet. I didn't complete it because I knew it would not be one I would wear, but it was a great learning experience and I am happy with the results for my first time trying something like this. I'll retire the piece to my work space to look back on when I am better at this down the road (hopefully).
So, here are the pictures. I'm happy to hear critiques, provided they are productive. Most of the flaws in the helmet I already noted during the build.

Wearing my dust mask. See the joy in my eyes?

"MC Labs" - closer to the cave that Tony Stark was being held hostage in during IM 1.

And the helmet - front, back and side. Yes, it is incomplete due to it's numerous flaws.

Well, it's back to the labs. Going to try another foam helmet with thinner foam this go round and try my hand at a fiberglass one as well.

 

[docholiday78]

Re: Another Iron Man - Mark III - first helmet (in)complete!

So I put together my first helmet. I didn't complete it because I knew it would not be one I would wear, but it was a great learning experience and I am happy with the results for my first time trying something like this. I'll retire the piece to my work space to look back on when I am better at this down the road (hopefully).
So, here are the pictures. I'm happy to hear critiques, provided they are productive. Most of the flaws in the helmet I already noted during the build.

Wearing my dust mask. See the joy in my eyes?

"MC Labs" - closer to the cave that Tony Stark was being held hostage in during IM 1.

And the helmet - front, back and side. Yes, it is incomplete due to it's numerous flaws.

Well, it's back to the labs. Going to try another foam helmet with thinner foam this go round and try my hand at a fiberglass one as well.

Excellent job for your first one, I also kept my first one so whenever I need a good laugh its there for me lol. Your doing great shape wise but the only advise is when you glue try small beads and press each part together and take your time then add more glue to back foam and go over front and melt excess glue and youll get a much cleaner seam. Lookin forward to seeing your progress

 

[MorbidCharlie]

Re: Iron Man - Mark III - first helmet (in)complete!

I completed another piece today - half of a shoulder. This piece is a complete 180 from the helmet, as I tried some new tricks.

I learned how to use a 45 degree cutter. Cutting at 45 degrees allows you to thin the foam at the edges for cleaner attachment lines. I also created "male" and "female" edges so that some of the edges would slide together. STEALTH mentions this in his tutorials as a tip from indiefilmgeek. If you're new, or not set in your cutting ways, you might give it a shot.

Since I'm using one large roll of foam, I decided to trace some of the pieces back to back creating one larger piece and heated it with a heat gun to form the shape better, removing the need to cut smaller pieces and eliminating some seams altogether.

Finally, I quit being so trigger happy with the glue gun (thanks docholliday78!) so the piece is cleaner.

I'm very happy with how this piece came out, especially since it is only the second piece I've ever created. If you look at DF's foam files, this piece is 5 pieces, but I cut it down to 4 by combing the two "front" pieces together. The next shoulder piece I try, I am going to try and cut it down to two: the top and one large front piece.