From cardboard to armor?

[Matches Malone]

Browsing the sight, I see many costumes being constructed first by cardboard then seeing 10 posts later a painted shiny piece of armor. I'm going to use Iron Man as an example as it seems he's the most reproduced costume on this board (which all look awesome!). What exactly are you guys doing with the cardboard once you've constructed your armor? All the detail in the middle is what I'd like to learn more about.

 

[SaberTech]

There are several methods ... fiberglass and resin ... then bondo or rondo to smooth the surface out are common ... some people have used drywall mud but it is not very strong and will not last wearing it ... others on this site will have tips to create great looking armor as well it all depends on exactly what method you use ... also some of us use cardstock instead of cardboard ... but i think there are great works here from all mediums used ... welcome to the RPF by the way

 

[Matches Malone]

Thanks for the heads up and the warm welcome. For the life of me I couldn't find anything that filled-in the process "in the middle" to get the final product. I've never handled fiberglass or resin. How do you guys get a hold of this stuff? The only type of resin I've come across has been on statues/maquettes I've collected.

There are several methods ... fiberglass and resin ... then bondo or rondo to smooth the surface out are common ... some people have used drywall mud but it is not very strong and will not last wearing it ... others on this site will have tips to create great looking armor as well it all depends on exactly what method you use ... also some of us use cardstock instead of cardboard ... but i think there are great works here from all mediums used ... welcome to the RPF by the way

 

[STEALTH]

This thread is the best example of what you want to know

Iron Man Mark 6- second cardboard build - by BlackDynamo1

Materials used are mostly

Fiberglass Resin, automotive body filler (refered to as Bondo), drywall compound like Saber mentioned.

all can be found at walmart or hardware store of somekind

 

[TC9948]

Welcome to the RPF. To be honest the middle work is the most boring to document as mixing the bondo and shaping it to the correct shape takes several coats and a lot of sanding to get to the final shape. I suggest starting off with a helmet or something small and see what you can do! The middle might be boring to document but it is the most fulfilling aspect as you can see your creation taking shape.